Measure a sandwich as served, then use a trial fold to find the paper needed for coverage and closure. Filled height and your folding method matter as much as length.
Record the filled sandwich envelope
Measure length, widest width and maximum filled height, including normal toppings. State whether the sandwich is whole, cut, toasted or served in another arrangement. Use the largest regular recipe that shares this wrap, rather than an unfilled bread measurement.
| Field | Record |
|---|---|
| Recipe/version | The actual serving build used in the trial |
| Envelope | Length × width × height, with units |
| Fold direction | Which edge crosses the food first |
| Closure | Intended overlap and how it is held |
| Other packaging | Any box, sleeve or carrying arrangement |
Use a trial sheet rather than a universal size formula
Fold a trial sheet using the same sequence staff will use. Mark the edges needed to cover the food, fold the ends and achieve the intended overlap. Unfold it, measure the used outline and repeat with the normal range of fills.
A simple rectangle formula can miss folds and rounded food shapes. Keep the marked trial and photos as the size-request reference. This is a geometry exercise; material performance still needs the proposed sample and intended food.
Keep seams and artwork away from the wrong places
Mark the visible top face, fold lines and closure area on the supplier-approved layout. Repeated patterns tolerate changes in visible position differently from a single centered message. Verify artwork with the chosen fold before approving production; the trial sheet is not a manufacturing dieline.
Turn the trial into a repeatable specification
- Attach the unfolded trial dimensions and units.
- Describe actual food contact and serving conditions.
- Identify the paper construction for supplier review.
- List quantity and artwork version per sheet format.
- Approve the final printed sample or layout for that reference.
Use wrap vs liner for the serving-job comparison and the sample record for observations.
BrandYourPack planning worksheet. Sample checks described here are steps for your project, not published test results. Confirm material, dimensions, print, quantities and intended use for the proposed reference before approval.
Questions about this decision
Can I choose the sheet from bread length alone?
No. Filled height, width, folds and intended overlap also use paper. Measure the completed sandwich and perform the trial fold.
Should I add a fixed overlap to every wrap?
Use the overlap needed by your fold and closure arrangement. There is no universal allowance established by this guide.
Is the trial sheet a production template?
No. It communicates fit and fold requirements. Use the final supplier-approved layout for printing and manufacture.
