How to Choose the Right Pack Size for Your Mission (20L vs 40L vs 80L)

At Squatch Survival Gear, we build rugged, American-made packs for people who actually use their gear. Not influencers chasing trends. Not folks buying equipment to sit in a closet. People who hike, train, work, travel, prepare, and sometimes find themselves carrying more than they planned.

Choosing the right pack size isn’t about what looks cool. It’s about matching the mission, the timeframe, and the load to the pack that won’t fail you when plans change, with or withour warning. 

This guide breaks down how to choose between a 20-liter, 40-liter, or 80-liter pack—and why the wrong size can cost you comfort, mobility, and capability when it matters most.

Why Pack Size Matters More Than Most People Think

Most pack failures aren’t material failures. They’re planning failures.

Too small, and you’re strapping gear to the outside, fighting balance, and digging thru the main compartment. 
Too big, and you’re carrying empty space, unnecessary weight, and fatigue you didn’t need.

The right pack carries what you need comfortably, securely, and efficiently—while leaving room for reality. Weather changes. Detours happen. Missions grow.

Let’s break it down.

20L Packs: Short Duration, High Mobility

A 20-liter pack is built for speed, efficiency, and tight movement. This is your grab-and-go size.

These packs shine when you’re moving fast and light. Urban environments. Day hikes. Travel days. Training sessions. Short missions where mobility matters more than capacity.

A properly designed 20L pack carries essentials without fighting your body. Water. Food. Medical. Layers. Tools. Navigation. No wasted space, no excess bulk.

This is where packs like the Mothman Backpack, and Rougarou live. Compact, durable, Berry-compliant, and comfortable under load—even when worn all day. It fits under airline seats, moves through crowds, and doesn’t scream “I’m overpacked.”

If your mission is measured in hours, not days, a 20L pack is often the smartest choice.

40L Packs: The Sweet Spot for Real-World Use

If there’s one size that handles the most real-world scenarios, it’s the 40-liter class.

This is your 24–72 hour capability range. Overnight trips. Bug-out flexibility. Field training. Weather uncertainty. Extra layers. Extra food. Extra water.

A good 40L pack balances structure and flexibility. It carries heavier loads without collapsing. It organizes gear without forcing a specific packing style. It adapts when a short walk turns into a long one.

This is where the Kakamora and Rockape excel. It’s not oversized, but it’s not fragile. It carries weight close to your body, distributes load properly, and stays comfortable when lesser packs start biting into shoulders and hips.

If you want one pack that can handle most situations, this size is hard to beat.

80L Packs: Extended Operations and Heavy Loads

An 80-liter pack is a tool—not a fashion statement.

This is extended duration. Multi-day trips. Cold weather gear. Extra food. Shelter. Mission-specific equipment. The kind of loads that punish poorly designed packs.

Big packs require structure. Frames. Load lifters. Proper suspension. If those elements aren’t right, you’ll feel it fast—numb fingers, hot spots, and fatigue that stacks quickly.

This is where large framed rucks like the Sasquatch Ruck Sack and Yowie Ruck Sack make sense. They’re designed to carry real weight, not just volume. They stabilize loads, protect your body, and let you move farther under stress.

If your mission requires carrying everything you need to survive on your back, this is the size that earns its keep.

Choose the Mission, Not the Trend

The biggest mistake people make is buying for a hypothetical scenario instead of their most likely reality.

Most people don’t need an 80L pack every day.
Most people outgrow cheap 20L packs quickly.
Most people benefit from owning one primary pack and one smaller secondary pack.

Your pack should support how you actually live, train, and prepare—not how social media tells you to look.

At Squatch Survival Gear, we design packs that solve real problems. Comfortable under load. Durable enough for hard use. Built in America by people who care about the work.

Because when your gear matters, there’s no room for guesswork.