9.875″ x 4.5″ x 13.5″ One Gallon Popcorn Bag

9.875″ x 4.5″ x 13.5″ One Gallon Popcorn Bag – Resealable Stand-Up Zipper Pouch

The standard one-gallon popcorn bag for gourmet popcorn shops, concessionaires, and gift retailers

If you sell popcorn at retail — gourmet caramel corn, kettle corn, cheese corn, gift tins replaced with pouches, holiday assortments, or concession stand take-home bags — this is the size you’ve been looking for. The 9.875″ x 4.5″ x 13.5″ One Gallon Popcorn Bag is the industry-standard one-gallon stand-up zipper pouch, engineered specifically for the demands of popped corn: light, voluminous, easily crushed, prone to going stale, and impossible to merchandise in a flat bag. This pouch solves every one of those problems and looks like premium packaging on the shelf while it does it.

Built on a 3.5 mil PET/PE lamination — the right film for popcorn

The bag is constructed from a 3.5 mil PET/PE laminate, the workhorse film structure for popcorn and other light, oxygen-sensitive snacks. The outer PET (polyester) layer delivers high optical clarity, dimensional stability under temperature change, and excellent print receptivity — important if you ever move from stock to a custom-printed version. The inner PE (polyethylene) layer is your sealant: clean, repeatable heat seals on impulse sealers, band sealers, and rotary pouch fillers. Together they give you a tough, low-pinhole-rate bag that holds its shape on the shelf and won’t tear during fill, ship, or display.

The PET/PE structure also provides a real moisture and gas barrier — meaningfully better than plain LDPE or polypropylene bags — which translates directly to longer shelf life on a product that lives or dies on crispness. Customers reach for popcorn that’s still crunchy on day 30, not day 3.

True one-gallon capacity, sized for popped product

The 9.875″ x 4.5″ x 13.5″ outside dimensions are calibrated for one gallon of finished popped popcorn — roughly 16 cups of popped volume, depending on kernel variety and fill density. That’s the sweet spot for gourmet retail: large enough to be a substantial gift or grab-and-go purchase, small enough to fit a standard shipping carton and a customer’s pantry shelf. Hand-fill operators love this size because one bag = one gallon scoop — no weighing, no second-guessing, no waste.

If you’re packing denser products like caramel corn (the caramel coating significantly increases bulk density), you’ll typically land at 12–14 oz net fill weight in this bag. For plain salted, kettle, or cheese corn, expect 6–10 oz net fill weight.

Resealable zipper — the feature your customers actually notice

Every bag includes a press-to-close, easy-open zipper just below a heat-sealable top header. That zipper is the single biggest factor in repeat purchase on popcorn. Customers open the bag, eat half, reseal it, and the product is still fresh the next day. A bag without a zipper gets eaten in one sitting or thrown out — either way you don’t get the credit for freshness. Reviews on this exact bag from verified buyers confirm the pattern: gourmet popcorn shops, gift packers, and concession operators all call out the resealable feature as the reason their customers come back.

The heat-seal header above the zipper gives you tamper evidence on the first sale: the customer cuts or tears off the sealed strip to access the zipper for the first time. After that, the zipper takes over.

Stand-up gusset — premium shelf presence, no boxes required

The 4.5″ bottom gusset is wide enough for true upright stability — even when the bag is partially empty, it stays square and faces the customer. That gives you a tall, vertical merchandising format that crushes flat pillow bags on retail shelves and replaces expensive chipboard boxes outright. You get the visual presence of a printed box at a fraction of the cost, with a real barrier laminate that chipboard simply cannot provide.

For brands moving from boxes to pouches, this is also a significant freight and storage win: a case of 250 flat pouches takes a fraction of the warehouse footprint of 250 chipboard boxes, and the bags arrive ready to fill — no assembly, no glue, no fold-down labor on your floor.

FDA-compliant, heat-sealable, food-contact safe

All films used in this bag are FDA-compliant for direct food contact. Heat-seal performance is broad-range and forgiving — most operators run between 280°F and 340°F on a band sealer depending on dwell time. The pouch handles cleanly on:

• Impulse sealers (the most common hand-fill setup)
• Continuous band sealers
• Pre-made-pouch rotary fillers
• Vacuum or gas-flush chambers (for brands extending shelf life with nitrogen flush)

What you can pack in it

While “popcorn bag” is in the name, this size is a workhorse for a range of light, voluminous snack products:

• Plain popcorn, kettle corn, caramel corn, cheese corn, chocolate-drizzled popcorn
• Puffed rice and puffed grain snacks
• Cotton candy and large-format confections
• Pretzels and pretzel mixes
• Cheese curls and puffed cheese snacks
• Trail mix, granola, and bulk cereal
• Dog treats, jerky bundles, and large pet treat assortments
• Cookies, biscotti, and bakery items in gift-pack quantities
• Holiday gift assortments and corporate gifting

Specifications

Ordering, lead time, and freight

This is a stocked item and typically ships within one to two business days. Freight is calculated at checkout from our USA warehouse. Wholesale buyers ordering pallets — contact us directly for case-quantity break pricing, consolidated freight, and standing-order setups for high-volume gourmet popcorn operations.

Ready to put your brand on it?

This stock bag is the sizing benchmark for one-gallon popcorn at retail. Once you’ve validated the size with your fill weight and shelf footprint, the natural next step is a custom-printed version of this exact bag with your logo, story, ingredient panel, and nutrition facts front and center. NFC Bags is a USA-based flexible packaging manufacturer and we print these in-house with low minimums for emerging gourmet popcorn brands and full production runs for established ones. Ask about a custom quote.