Wicketed Poly Bags - High-Speed Dispensing for Bakery and Produce Operations

Pre-opened gusseted poly bags mounted on wire wickets for rapid one-handed dispensing in high-volume bakery, deli, and produce operations. These wicketed bakery bags feature bottom gusset construction for dimensional stability and expanded capacity, combined with pre-separated mounting on dispensing wickets for maximum operational efficiency. Clear LDPE (Low-Density Polyethylene) film provides product visibility while maintaining FDA compliance for direct food contact applications.

Standard inventory includes sizes from 7.25" x 13.125" through 14" x 20" with gusset depths from 2" to 4.5". Available in 1 mil and 1.25 mil gauges with wicket packaging of 100-250 bags per wicket depending on size. Perforated lip design enables quick bag separation from wicket during high-speed bagging operations. All bags manufactured from virgin LDPE resin meeting FDA 21 CFR 177.1520 specifications for food packaging.

Browse standard sizes below or contact us for custom wicketed bag specifications. Technical questions about dispensing equipment compatibility or custom sizes? Call 800-569-1266 (M-F 8:30-5 EST).

Wicket System Design and Operational Mechanics

Wire Wicket Mounting Configuration

Bags are precisely stacked and penetrated by parallel metal wickets creating ready-to-dispense packages:

• Wicket material: Galvanized steel wire (corrosion-resistant)
• Wicket spacing: 3" to 9" center-to-center (application-specific)
• Wicket length: 3" to 6" (matched to bag width)
• Bags per wicket: 100-350 units depending on bag size and gauge
• Perforation line: Micro-perforations on lip allow clean separation from wicket
• Stack orientation: Bags oriented face-forward for immediate access

The wicket system provides three critical operational advantages: (1) Bags remain separated and ready to open eliminating bag-to-bag adhesion, (2) One-handed dispensing allows simultaneous product handling, (3) Pre-counted quantities on wickets simplify inventory management.

Dispensing Operation Sequence

Operational workflow for wicketed bag systems:

1. Mount wicket: Load wicket package onto compatible dispenser or mounting posts
2. Access bag: Grasp front-most bag by lip area (bags naturally separate)
3. Tear perforation: Pull bag forward - perforation tears cleanly from wicket wires
4. Open bag: Bag gusset automatically expands as removed from stack
5. Insert product: Bottom gusset provides stable base for product loading
6. Repeat cycle: Next bag immediately accessible for continuous operation

Average dispensing time: 1-2 seconds per bag in practiced high-volume operations. Significantly faster than manual bag separation from bulk rolls or case packs.

Bottom Gusset Construction Details

Gusseted bottom provides dimensional stability and increased capacity:

• Gusset configuration: Side-sealed expanding bottom panel
• Gusset depths: 2", 2.5", 4", 4.5" standard options
• Expansion mechanism: Folded construction expands when bag fills
• Base stability: Expanded gusset creates flat rectangular base
• Capacity increase: 40-60% greater volume vs. equivalent flat bag
• Standing capability: Filled bags stand upright on counter or shelf

Bottom gusset construction is critical for irregular-shaped products (artisan breads, baguettes, produce) that require dimensional accommodation beyond simple flat bag geometry.

Material Specifications and Performance Characteristics

Low-Density Polyethylene (LDPE) Film Properties

Manufactured from virgin LDPE resin with performance optimized for food packaging:

• Gauge range: 1 mil (0.001") and 1.25 mil (0.00125") standard thicknesses
• Tensile strength: Adequate for 2-5 lb product loads depending on size
• Puncture resistance: Moderate - suitable for soft/medium-hardness items
• Flexibility: High - conforms to irregular product shapes
• Moisture barrier: Good protection from ambient humidity
• Temperature range: -40°F to 160°F operational limits
• Optical clarity: Clear/translucent (not crystal-clear like BOPP)

1 Mil vs. 1.25 Mil Gauge Selection

1 mil gauge applications:

• Lightweight products (breads, pastries, cookies, bagels)
• Product weight <2 lbs per bag
• Smooth or soft-surfaced items without sharp edges
• Maximum cost efficiency for high-volume operations

1.25 mil gauge applications:

• Heavier products (large artisan loaves, bulk produce)
• Product weight 2-5 lbs per bag
• Items with moderate surface irregularities
• Enhanced puncture resistance for crusty breads
• Reduced risk of bag failure during customer handling

Cost differential: 1.25 mil bags approximately 20-25% higher cost than equivalent 1 mil bags. Evaluate product characteristics and failure rate economics when selecting gauge.

FDA Compliance and Food Safety

All wicketed bags manufactured to meet food contact regulations:

• FDA 21 CFR 177.1520: Olefin polymers compliance for food contact
• Virgin resin: 100% virgin LDPE (no recycled content) ensures purity
• Direct food contact: Approved for all food types without restrictions
• No migration: Virgin polymer formulation prevents chemical migration
• USDA compliance: Meets USDA specifications for institutional food service
• Kosher certification: Available upon request for qualifying facilities

Application Engineering: Bakery Operations

Artisan Bread Packaging

Wicketed bags engineered for commercial bakery bread packaging:

Crusty artisan loaves: 1.25 mil gauge recommended for crusty surfaces that can puncture thinner films. Bottom gusset (4"-4.5") accommodates irregular shapes and provides stable base for display. Sizes 10" x 15" through 14" x 20" handle most artisan bread formats.

Sandwich breads and soft rolls: 1 mil gauge adequate for smooth-crusted products. Smaller gussets (2"-2.5") sufficient for uniform loaf shapes. Sizes 9" x 15" through 11" x 17" cover standard bread applications.

Baguettes and long-format breads: Extended length bags (up to 20" long) with narrow widths (6"-8") and moderate gussets. Custom sizing often required - see custom ordering specifications below.

Deli Counter Applications

Point-of-sale bagging for prepared foods and deli items:

• Sandwiches: Medium sizes (9" x 14" to 11" x 14") with 2"-4" gussets
• Salads and prepared foods: Container accommodation requires matching gusset to container depth
• Bulk deli items: Cheese blocks, cold cuts, prepared entrees in larger formats
• Bakery case items: Cookies, pastries, muffins, croissants

Wicket dispensers typically mounted at counter height for staff access during customer service. Pre-opened bags significantly reduce service time during peak periods.

Produce Department Operations

Fresh produce packaging and bulk item dispensing:

• Celery, broccoli, lettuce: Printed produce bags with vegetable graphics
• Bulk items: Potatoes, onions, apples, citrus in larger gusseted formats
• Specialty produce: Mushrooms, herbs, specialty vegetables
• Weighing integration: Bags sized to fit on scale platforms without interference

Note: Standard LDPE wicketed bags provide moisture protection but limited gas exchange. For products requiring ventilation (crusted breads, certain produce), consider micro-perforated wicketed bags as alternative.

Size Selection Engineering

Dimensional Notation Standards

Wicketed bag dimensions specified as: Width x Length x Gusset Depth + Lip Length

Example: 11" x 18" x 4" + 1.5"

• 11" = Bag width (opening dimension)
• 18" = Bag length (depth when expanded)
• 4" = Bottom gusset depth (adds capacity)
• 1.5" = Lip length (extends beyond bag for wicket mounting)

Critical note: Bag length measurement is total length from lip fold to bottom seal, NOT including the extended lip. Usable interior length = Listed length dimension.

Product-to-Bag Sizing Protocol

For bread and baked goods:

1. Measure product at maximum dimensions (length x width x height)
2. Width: Add 1" to product width for insertion clearance
3. Length: Add 2" to product length for bag closure and twist-tie space
4. Gusset: Select gusset depth equal to or exceeding product height

Example calculation - Standard sandwich loaf:

• Product: 9" long x 4.5" wide x 4" high
• Minimum width: 5.5" (4.5" + 1")
• Minimum length: 11" (9" + 2")
• Minimum gusset: 4" (matches height)
• Select: 9.25" x 15" x 4" bag (provides margin)

Standard Size Range and Applications

Small format (7-9" width):

• 7.25" x 13.125" x 2.5" - Sandwich bags, small pastries
• 9" x 15" x 2.5" - Individual rolls, bagels, standard sandwiches
• 9.25" x 14.5" x 2" - Flatbreads, pitas, specialty applications

Medium format (10-11" width):

• 10" x 15" x 4" - Standard bread loaves, medium pastries
• 10" x 16" x 4" - Large loaves, pastry assortments
• 11" x 14" x 4" - Wide loaves, specialty breads
• 11" x 17" x 4" - Large artisan breads
• 11" x 18" x 4" - Extra-large loaves, bulk items

Large format (12-14" width):

• 12" x 19" x 4" - Oversized artisan breads, bulk products
• 14" x 20" x 4" - Maximum capacity applications

Custom Wicketed Bag Specifications

Custom Ordering Requirements

When standard sizes don't meet operational requirements, custom wicketed bags can be manufactured to specification. The following parameters must be specified for accurate custom quotes:

1. Bag Dimensions

• Width: 4" to 24" (opening dimension)
• Length: 8" to 48" (bag depth)
• Gauge: 0.75 mil to 2.0 mil thickness

2. Bottom Gusset Specification

• Gusset depth: 0" (flat bag) through 12" depth
• Gusset style: Standard side-seal or specialty configurations

3. Lip Length and Release Type

• Lip length: 1" to 3" extension beyond bag body
• Release mechanism: Perforated lip (standard) or tear notches
• Perforation pattern: Micro-perforations for clean separation

4. Wicket Configuration

• Wicket length: 3" to 6" (must exceed bag width)
• Wicket spacing: 3" to 9" center-to-center between parallel wires
• Bags per wicket: 100-350 bags (based on gauge and size)

5. Cardboard Header Options

• No header (bags only on wicket)
• Front header (product information/branding facing forward)
• Back header (mounting instructions/specifications)
• Double header (both front and back)

6. Printing Specifications (Optional)

• Print colors: 1-6 color flexographic printing
• Print area: Front panel, back panel, or both
• Artwork: Logo, product information, branding, regulatory text
• Minimum order quantity: Typically 10,000-50,000 bags for custom printing

Custom Order Minimum Quantities

• Plain bags (no printing): 5,000-10,000 bags minimum depending on size
• 1-2 color printing: 10,000 bags minimum
• 3+ color printing: 25,000-50,000 bags minimum
• Complex specifications: Higher minimums may apply for unusual configurations

Lead time for custom wicketed bags: 3-6 weeks from artwork approval and order confirmation. Expedited production available for premium pricing.

Wicket Dispenser Equipment Integration

Dispenser Types and Mounting

Countertop dispensers:

• Freestanding units for point-of-sale counters
• Wicket posts match bag wicket spacing (3"-9")
• Typical capacity: 2-4 wicket stacks (200-1000 bags)
• Material: Stainless steel or powder-coated steel

Wall-mounted dispensers:

• Space-saving installation for prep areas
• Single or multi-wicket configurations
• Height-adjustable for ergonomic access
• Stainless steel construction for sanitary environments

Under-counter dispensers:

• Hidden storage with pull-through access
• Maintains clean counter appearance
• Large capacity for high-volume operations
• Gravity-feed or spring-loaded mechanisms

Dispenser-to-Bag Compatibility

When specifying wicketed bags, ensure wicket configuration matches existing dispensers:

• Wicket spacing: Dispenser post spacing must match bag wicket spacing exactly
• Post diameter: Standard 3/16" diameter posts accommodate most bags
• Post length: Posts must exceed maximum wicket stack height
• Load capacity: Verify dispenser weight rating supports loaded wicket stack

If purchasing new dispensers, provide bag wicket specifications to equipment supplier to ensure compatibility.

Operational Efficiency and Cost Analysis

Labor Savings vs. Bulk Roll Bags

Comparative analysis of wicketed bags vs. alternative packaging methods:

Factor	Wicketed Bags	Bulk Roll Bags
Dispensing time	1-2 seconds per bag	3-5 seconds per bag
Bag opening effort	Pre-separated (minimal effort)	Manual separation required
One-handed operation	Yes	No (requires two hands)
Bag waste from adhesion	Minimal (<1%)	Moderate (2-5%)
Inventory counting	Easy (pre-counted wickets)	Difficult (estimate only)
Unit cost	15-25% premium	Lower base cost
Best for	High-volume point-of-sale	Back-room prep operations

Volume-Based Economics

Wicketed bags justify premium pricing in high-volume operations:

• Labor cost reduction: 2-3 seconds saved per transaction × 200 transactions/day = 10-15 minutes daily labor savings
• Peak period efficiency: One-handed operation allows simultaneous customer service tasks
• Reduced waste: Pre-separated bags eliminate adhesion-related waste
• Inventory accuracy: Pre-counted wickets improve stock management

Break-even analysis: Operations bagging >100 items/day typically recover wicketed bag premium through labor efficiency within 30-60 days.

Storage and Handling Specifications

Warehouse Storage Requirements

• Temperature: Store at 40-90°F (avoid temperature extremes)
• Humidity: 30-70% relative humidity prevents film brittleness or tackiness
• Light exposure: Minimize UV exposure to prevent polymer degradation
• Stacking limits: Maximum 5 cases high to prevent wicket deformation
• Case orientation: Store flat - do not store on edge or end

Shelf Life and Quality Maintenance

• Shelf life: 24 months from manufacture date under proper storage
• Film degradation: Excessive heat causes polymer softening and bag adhesion
• Static buildup: Low humidity increases static - may affect dispensing
• Wicket integrity: Rough handling can bend wickets affecting dispenser compatibility

Quality Standards and Manufacturing Specifications

Manufacturing Tolerances

• Dimensional tolerance: ±3% on width and length measurements
• Gauge tolerance: ±10% on film thickness
• Wicket spacing tolerance: ±1/8" on center-to-center spacing
• Perforation quality: Clean separation with minimal tearing force
• Seal integrity: Heat seals tested for leak-free performance

Quality Control Testing

Wicketed bags undergo multi-point quality verification:

• Dimensional inspection on statistical sampling
• Gauge verification using micrometer measurement
• Perforation pull-test for separation force
• Seal strength testing to verify weld integrity
• Wicket alignment and penetration inspection
• Bag count verification per wicket

Ordering Information and Package Quantities

Standard case quantities:

• Small/medium bags: 1,000 bags per case (typically 4-5 wickets of 200-250 bags)
• Large bags: 500-1,000 bags per case (2-5 wickets depending on size)
• Custom orders: Quantity per case specified at time of order

Minimum order quantities:

• Standard sizes: 1 case minimum order
• Custom plain bags: 5,000-10,000 bags minimum
• Custom printed bags: 10,000-50,000 bags minimum (varies by complexity)

Technical Support and Custom Ordering Assistance

Our packaging engineers provide comprehensive support:

• Product-to-bag sizing calculations and recommendations
• Gauge selection for specific applications and product weights
• Custom bag specification development from product samples
• Dispenser compatibility verification
• Custom printing artwork assistance and proofing
• Volume pricing for contract manufacturing arrangements

Contact technical support: 800-569-1266 (M-F 8:30-5 EST)

Custom quote requests: Provide the 8 specifications listed in "Custom Wicketed Bag Specifications" section above for fastest turnaround. Include product photos or samples when possible for optimal sizing recommendations.