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Form-fit geometry | Polyethylene (PE)

Custom 3D Bags and Oversized PE Bags

Three-dimensional industrial bags built around the packed envelope. Custom 3D bags, form-fit PE bags and bespoke polythene bags manufactured to your length, width and height so the film follows the product, not a catalogue grid. Film thickness 25 to 300 microns.

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25 to 300 microns Custom L x W x H No fixed catalogue-size limit Polyethylene (PE) Form-fit free volume

What a custom 3D bag is

A 3D bag is a flexible package with three working dimensions: length, width and height. Industrial teams also use form-fit bag, box-shaped bag, oversized PE bag or bespoke polythene bag for the same idea. Compared with an oversized flat bag, a purpose-designed 3D construction can reduce excess film, loose folds and handling interference around the packed object. A custom 3D bag is cut and sealed so free volume matches the load you ship or store.

This page covers geometry and general polyethylene construction. For enclosed corrosion-protection applications use VCI 3D bags. For enhanced moisture-barrier protection in a sealed pack use barrier 3D bags. Slip-on pallet protection: pallet covers. Dry bulk in a shipping container: container liners.

Oversized industrial load fully enclosed in a blue form-fit polyethylene 3D cover on a steel skid

Example of oversized equipment enclosed in a form-fit blue PE cover: the film follows the packed envelope rather than a stock bag size.

Where custom 3D bags are used

ApplicationWhy form-fit helps
Irregular parts and assembliesDefined height reduces bagging slack and handling snags
Oversized componentsNo forced fold into a catalogue size
Machinery free volume (non-VCI)Dust and handling cover shaped to the unit
Crate or box outer cover3D cover over a known outer envelope
Export staging (film only)Flexible layer before or after structure

Flexible bags do not replace immobilisation or wooden export crates when the load needs structure. Pair film decisions with how to pack a machine for export when building a full system.

Manufacturing parameters

ParameterWhat BENZ supplies
Film thickness25 to 300 microns
Base filmsPolyethylene (PE)
GeometryForm-fit 3D, gusseted and oversized constructions
SizeCustom dimensions; no fixed catalogue-size limit
OptionsUV stabilization, anti-static film and print when the construction allows
ClosureOpen cover, tape or heat seal as specified

How to measure

Take maximum length, width and height of the item as packed, including skids, motors, valves, panels and temporary packaging under the bag. If the load is not a clean cuboid, measure the bounding box and name protrusions. Add clearance only for fit or heat-seal access. Undersize and the bag fights the load. Oversize and you reintroduce the slack you paid to remove. State closure: open cover, tape, heat seal or other.

Enquiry checklist

DetailWhy it matters
Maximum packed L x W x HSets the only size that actually fits
Object typePart, assembly, machine, crate exterior, other
Protection requirementDust, handling, corrosion protection or moisture-barrier protection
Film and thicknessPolyethylene (PE), or route to VCI / barrier; 25 to 300 microns
Quantity and laneLot size; storage, domestic transit or export
Photo or drawingRequired for irregular or asymmetric shapes

Common mistakes

Ordering from a stock grid and fighting the fit. Measuring the bare machine then shipping it on a taller skid. Using pallet-cover language when the load is not palletized. Expecting polyethylene alone to replace barrier film or VCI protection. Skipping quantity and lane so the first quote is incomplete. Fix measure and risk first; manufacture is then straightforward.

Common questions

What is a custom 3D bag?

A three-dimensional flexible bag or cover manufactured to length, width and height so it follows the packed object. It is also called a form-fit bag, box-shaped bag, oversized PE bag or bespoke polythene bag depending on the application.

How is a 3D bag different from a flat poly bag?

A flat bag is mainly width and length. A 3D bag is engineered with height so large or irregular loads sit in a defined free volume with less wasted film and fewer weak corner folds.

What film thickness can you supply?

BENZ can supply film constructions from 25 to 300 microns, with thickness selected according to the packed product, geometry, handling conditions, puncture or tear risk, exposure and closure method.

Is there a maximum size?

There is no fixed catalogue-size limit. Made-to-order 3D bags are engineered from the packed envelope, material and fabrication method, including oversized and non-standard shapes.

Is this the same as a pallet cover or container liner?

No. A pallet cover is usually a slip-on hood for a palletized load. A container liner lines a shipping container for dry bulk. A custom 3D bag is the form-fit free-volume package for the item or shape you define.

What should I send for a quote?

Maximum packed L x W x H including protrusions; what you are packing; dust, handling, corrosion protection or moisture-barrier protection; film preference if known; thickness in microns if known; quantity; storage vs inland vs export. A photo or drawing helps irregular shapes.

Need a form-fit size that is not in a catalogue?

Send your dimensions and what you are packing. We will quote a 3D bag construction and flag if VCI or barrier film is the better route.

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