When Flat Isn’t Enough: Introducing Vela™ Gusset

Introducing Vela™ Gusset, designed for apparel that requires additional depth and support.

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For many apparel categories, standard flat bags provide a simple, efficient packaging solution. But not every garment is flat.

Structured shirts, collar-supported garments, knitwear, hoodies and lightweight jackets often require additional depth to maintain their shape, improve presentation and avoid unnecessary compression during packing, shipping and storage.

As brands continue their transition away from plastic packaging, finding a paper-based solution that accommodates these products without compromising performance can be a difficult.

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Why Additional Volume Matters

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Traditional flat bags are designed to minimize material usage and maximize operational efficiency. However, when packaging bulkier or more structured garments, brands may encounter issues such as:

- Collar deformation

- Product compression

- Reduced packing consistency

- Increased stress on the packaging itself

In these situations, additional internal space can make a significant difference.

Introducing Vela™ Gusset

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Vela™ Gusset is a new bag configuration designed to provide extra internal volume where it matters most. By incorporating an integrated bottom gusset, the bag creates additional depth while maintaining the familiar Vela experience and preserving compatibility with existing packing operations.

The result is a paper packaging solution that better accommodates structured and bulkier apparel without significantly increasing the overall footprint of the bag.

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Applications and Key Benefits

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Vela™ Gusset has been developed for apparel categories that require additional depth and support, including dress shirts with collar boards, structured collared garments, knitwear, hoodies, lightweight jackets and other folded products with greater volume. By creating extra internal space where it matters most, Vela™ Gusset helps brands protect garment presentation, improve packing consistency and reduce product compression. 

By creating additional space where it matters most, Vela™ Gusset delivers four key benefits:‍

- Extra Internal Volume: The integrated gusset creates additional space for collared shirts, knitwear and other garments that require greater depth.‍

- Collar Shape Protection: Additional volume helps maintain collar boards and garment structure throughout packing, transit and storage.‍

- Reduced Product Compression: Garments fit more naturally within the bag, helping reduce pressure on folded products and support better presentation upon arrival.‍

- Improved Packing Efficiency: Additional depth allows products to be packed more consistently, reducing the need to force garments into undersized packaging.

Designed Within the Vela Platform

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Vela™ Gusset extends the Vela™  portfolio while maintaining the principles that define the platform. The solution remains fully recyclable, FSC™ certified (FSC™ C102652), logistics ready and compatible with existing Vela printing and production capabilities.

For brands looking to replace plastic packaging across a wider range of apparel categories, Vela™ Gusset provides an additional option without introducing unnecessary complexity.

More Space. Better Structure. Same Vela Simplicity.

Because some garments simply need a little more room.