TSA Approved Quart Size Bag Dimensions – The Ultimate Professional Guide for OEM & Travel Brands

Compliance Note: Non-compliant toiletry bags can result in shipment rejections, customs delays, and potential liability if marketed as “TSA-approved” without verifiable specifications.

• 3.4 ounces (100 mL) or less per container
• 1 quart-sized, clear, resealable plastic bag
• 1 bag per passenger

• Transparency: Fully clear sides and seams
• Resealability: Zip-lock, slider, or double-seal closures
• Capacity: Approx. 1 quart = 32 fl oz ≈ 946 mL
• Dimensions: Typically 7 × 8 in (17.8 × 20.3 cm)

Design Tip: Keep the total volume below 1 L (946 mL) including the closure gusset. Excessive seam depth can cause the bag to exceed TSA’s perceived quart capacity.

Measurement	Imperial	Metric
1 Quart	32 fl oz	946 mL
3.4 oz limit	100 mL	100 mL
Typical Bag	7 × 8 in	17.8 × 20.3 cm

• Thickness: 0.3 – 0.5 mm (optimum balance of flexibility and strength)
• Sealing Method: Heat-sealing or RF-welding to prevent leaks
• Closure Type: Slider zippers, double-press seals, or hook-loop hybrid systems
• Edge Treatment: Rounded corners to prevent puncture or tearing

Compliance Note: Avoid opaque brand panels larger than 15 % of surface area; TSA officers may reject bags that obstruct visibility.

• American Airlines: accepts up to 8 × 8 in
• Delta & United: recommend 6 × 9 in
• EU airports: follow 20 × 20 cm strict rule

Material	Transparency	Durability	Temperature Resistance	Eco Profile	Cost Level
PVC (Polyvinyl Chloride)	Excellent	High	−10 °C – 70 °C	Moderate (contains chlorine)	★
PEVA (Polyethylene-Vinyl Acetate)	Excellent	Medium	−15 °C – 80 °C	Good (chlorine-free)	★★
TPU (Thermoplastic Polyurethane)	Crystal Clear	Excellent	−30 °C – 90 °C	Excellent (biodegradable options)	★★★

• PVC Bags: Economical, ideal for mass retail, but may yellow over time.
• PEVA Bags: Soft, flexible, and free of phthalates — a preferred option for eco-conscious brands.
• TPU Bags: Premium choice offering resilience, cold-crack resistance, and long-term clarity.

Material Insight:
FY recommends TPU for high-end cosmetic brands seeking long-lasting clarity and PEVA for brands prioritizing environmental positioning.

• REACH / RoHS (EU)
• CPSIA / Prop 65 (US)
• EN 71-3 / GB 4806 (chemical migration limits)

Compliance Note: FY’s production lines are audited under BSCI and ISO 9001, ensuring every shipment passes AQL 2.5/4.0 inspections.

For OEM/ODM toiletry bag manufacturers, the process begins with detailed CAD dimensional drafting.
Engineers simulate bag volume within 946 mL limits while optimizing structural rigidity.

Typical workflow:

1. Design Analysis: Confirm quart capacity, zipper tension, and corner radius.
2. Material Sourcing: Select PVC/PEVA/TPU based on client branding.
3. Sampling: Die-cut + RF weld prototypes.
4. Performance Testing: Leak test, transparency check, tensile test (≥10 N).
5. Mass Production: Batch QA under ISO 9001 standards.

Design Tip: Always verify the “filled geometry” — bags that appear smaller when empty may exceed 1 L when fully expanded, violating TSA quart-size definitions.

Test Type	Standard	FY Reference
Transparency	ASTM D1003	≥ 85 %
Seal Strength	ASTM F88	≥ 10 N
Odor / VOC	ISO 16000	Non-detectable
Cold Crack	ASTM D2136	−25 °C
Aging Test	FY Lab #A-TPU-2025	100 hr @ 60 °C

Compliance Note: Always include “Inspection Certificate” with shipment; many US importers now require documentation verifying quart-size compliance.

• “TSA Approved Quart Size Bag” (with caution note)
• Material composition (PVC/TPU/PEVA)
• Country of origin (“Made in China”)
• Barcode & inner polybag for retail

Design Tip: For Amazon FBA, keep outer carton under 25 kg and label with FNSKU; FY can print & apply per client request.

Region	Limit per Container	Bag Volume	Remarks
USA (TSA)	3.4 oz / 100 mL	1 quart (≈946 mL)	“3-1-1 Rule”
EU / UK	100 mL	1 L	Similar to TSA
Canada (CATSA)	100 mL	1 L	Enforced strictly
Australia / NZ	100 mL	1 L	Must fit flat bag
Japan / Korea	100 mL	1 L	Often require resealable zip
China (CAAC)	100 mL	1 L	Domestic adoption of TSA rule

• EU airports inspect quart bags more strictly under transparent lighting.
• Some Asia-Pacific airports request separate liquid inspection trays.
• US airports often allow flexibility if bags remain flat and clear.

Compliance Note: Always design packaging inserts in English + bilingual labels for EU/Asia to minimize misunderstanding at customs or security gates.

Item	Recommended Size	Material	Tip
Shampoo / Conditioner	≤ 3 oz (100 mL)	PE Bottle	Keep upright
Lotion / Cream	≤ 3 oz	Soft Tube	Avoid excess air
Toothpaste	Travel size	Laminated Tube	Seal tightly
Perfume / Spray	≤ 3 oz	Glass / Plastic	Use atomizer
Makeup Remover	≤ 3 oz	Drop Bottle	Wrap in film

Design Tip: Add internal gusset or divider to stabilize bottles during inspection handling.

Airline	Carry-On Limit	Notes
American Airlines	22 × 14 × 9 in	Liquids follow TSA 3-1-1
Delta Air Lines	22 × 14 × 9 in	Same standard
British Airways	56 × 45 × 25 cm	EU 1 L rule
Air France / KLM	55 × 35 × 25 cm	EU standard
ANA / JAL	55 × 40 × 25 cm	Strict visual inspection

Compliance Note: Design sample photos should clearly show dimensions on packaging artwork to reassure airline compliance officers.

• Monthly Output: 300 000 pcs
• Facilities: RF heat-sealing, ultrasonic welding, precision cutting
• Certifications: BSCI, ISO 9001, CPSIA, REACH, Prop 65
• Clients: Retail brands, travel accessory labels, airline suppliers

Material Insight: FY supports sustainable transitions—introducing bio-based TPU and recycled PEVA programs by 2026.

• OEM: We produce to your existing design specs.
• ODM: We develop new designs based on your concept, provide 3D mockups and prototypes.
• Private Label: Logo printing, custom packaging, barcode management.

Design Tip: FY’s in-house design team can adjust visual branding placement (<15 % opaque area) to maintain TSA transparency compliance.

Q1. Are all clear toiletry bags TSA-approved?

Not exactly. Only those meeting size (~1 quart), transparency, and resealability standards will pass checkpoints.

Q2. Can I use frosted or tinted clear bags?

Light tinting is often accepted, but opaque or patterned bags may be rejected.

Q3. How long do TPU bags last?

Typically 3–5 years with proper care; TPU resists cracking and discoloration.

Q4. What’s the safest printing method for TSA bags?

Use silk-screen or UV printing limited to <15 % coverage; FY ensures durability and ink compliance.

Q5. Can FY assist with Amazon FBA labeling?

Yes. FY provides barcode printing, carton labeling, and shipment consolidation.