Custom Sachet Packaging
Runlong provides custom sachet packaging for powders, seasonings, coffee, drink mixes, sauces, supplements, cosmetics and single-use samples. Choose custom dimensions, barrier materials, seal styles and printing methods to match your product and filling process.
- Custom Sizes
- 3-Side & 4-Side Seal
- Digital & Gravure Printing
- Premade Sachets & Rollstock
What Is Custom Sachet Packaging?
Custom sachet packaging is a compact flexible packaging format commonly used for single-use, sample-size and portion-controlled products. Sachets are usually flat and can be designed for powders, granules, sauces, liquids, creams and other products.
Custom sachet packaging can be supplied as finished premade sachets or as printed rollstock for automatic form-fill-seal machines. The correct format depends on your product, filling equipment, sealing temperature, barrier requirements and expected shelf life.
- Custom width, height and seal dimensions.
- Multiple barrier laminate structures.
- Front and back custom printing.
- Tear notch and easy-open options.
- Suitable for both food and non-food applications.
For larger flat premade pouches, see our Custom Three Side Seal Pouches .
Custom Sachet Packaging vs. Stick Pack Packaging
Sachets and stick packs both work well for single-use products, but the package shape, artwork area and filling setup are different.
| Comparison | Sachet Packaging | Stick Pack Packaging |
|---|---|---|
| Typical Shape | Square, rectangular or compact flat pouch | Long and narrow |
| Typical Products | Sauces, seasonings, powders, skincare samples, cosmetics and drink mixes | Coffee, electrolyte powder, protein powder, supplements and granules |
| Common Seal Styles | 3-side seal, 4-side seal and back/fin seal | Back seal or 3-side seal |
| Artwork Area | Wider display area for graphics and information | Narrower vertical artwork layout |
| Typical Use | Broad range of single-serve and sample products | Efficient narrow single-dose packaging |
Need a narrow single-dose format? View Custom Stick Pack Packaging .
Custom Sachet Packaging Formats
The best sachet format depends on your product, filling process, seal layout and machine configuration.
3-Side Seal Sachets
Three sealed edges with one side used for filling before final sealing. Common for powders, samples and portion packs.
4-Side Seal Sachets
Visible sealing on all four edges creates a balanced flat format frequently used for single-use products and samples.
Back / Fin Seal
Film wraps around the product and is joined at the back. Compatibility depends on your filling and packing process.
Premade Sachets
Finished empty sachets can be supplied for customers who have compatible filling and sealing equipment.
Printed Rollstock
Printed film rolls are designed for automatic machinery that forms, fills and seals each sachet.
Connected Sachets
Perforated strips and connected sachets require project-specific review based on size, perforation and filling equipment.
Custom Sachet Packaging for Different Products
Runlong custom sachet packaging can be designed for food, beverage, supplements, cosmetics and personal-care products.
Sauces & Condiments
Portion sachets for ketchup, chili sauce, dressing and other liquid or semi-liquid food products.
Spices & Seasonings
Small custom sachet packaging for seasoning powders, spice blends and soup mixes.
Coffee
Single-serve sachets for instant coffee, cappuccino, cocoa and powdered coffee beverages.
Drink Mixes
Printed sachets for electrolyte powder, fruit drink powder and flavored beverage mixes.
Protein & Supplements
Portion packaging for protein powder, collagen, supplements and sports nutrition.
Wellness Powders
Compact sachets for vitamin powders, probiotic products and hydration mixes.
Personal Care
Sample sachets for shampoo, conditioner, lotion, gels and personal-care products.
Skincare & Cosmetics
Printed flexible packaging for sheet masks, skincare products and cosmetic samples.
Tea
Printed outer sachets for tea bags and specialty single-serve tea products.
Materials for Custom Sachet Packaging
Material structure is one of the most important decisions in custom sachet packaging. Moisture, oxygen, light, aroma, oil, filling temperature and expected shelf life can all affect the final laminate selection.
The final structure should be confirmed using the actual product, filling process and market requirements rather than choosing material by appearance alone.
Printing Options for Custom Sachet Packaging
Digital printing is useful for smaller quantities and multiple SKUs, while gravure printing becomes more economical for larger stable orders.
Digital Printing
Digital printing is suitable for product launches, smaller quantities, multiple designs and projects where artwork may change frequently.
- Can start from around 100 pcs for suitable projects.
- 1,000–3,000 pcs is often a practical order range.
- No gravure cylinder setup fee.
- Useful for multiple SKUs and market testing.
Gravure Printing
Gravure printing is generally more suitable when artwork is stable, order quantities are larger and the same packaging will be reordered.
- Typical MOQ is around 10,000 pcs for suitable projects.
- Around 8,000 pcs, comparing gravure economics is worthwhile.
- 40,000+ pcs usually favors gravure for repeat orders.
- Printing cylinders are typically about USD 30–80 per color.
Premade Sachets or Printed Rollstock?
The filling process determines whether you need completed empty sachets or printed packaging film supplied on rolls.
Premade Sachets
Empty sachets are manufactured first and supplied for filling and final sealing on compatible equipment.
Printed Rollstock
Packaging film is supplied in rolls for automatic machinery that forms, fills and seals the sachet.
Machine Specifications
Rollstock projects may require film width, repeat length, eye-mark position, unwind direction and machine information.
Using an automatic packaging machine? View Rollstock Film Packaging .
Custom Sachet Packaging Development Process
A successful custom sachet packaging project should begin with the product and filling method rather than artwork alone. Confirming technical details early helps reduce sealing, sizing and machine-compatibility problems.
Quality Control for Custom Sachet Packaging
Dimensions, sealing, print registration and material documentation should be reviewed according to the requirements of each project.
Learn more on our Packaging Compliance page. General information on food-contact packaging is also available from the U.S. Food & Drug Administration .
Information Needed for a Custom Sachet Packaging Quote
Providing the basic specifications helps us determine the suitable sachet format, material structure and printing method.
- Product type.
- Fill weight or fill volume.
- Required width and height, if known.
- Estimated order quantity.
- Number of artwork designs or SKUs.
- Premade sachet or rollstock requirement.
- Barrier or shelf-life requirements.
- Artwork or reference packaging image.
- Filling-machine information for rollstock projects.
- Destination market and documentation requirements.
Not Sure Which Sachet Format You Need?
Send us your product, target fill weight, estimated quantity and a photo of the packaging style you want. We can help evaluate whether custom sachet packaging, stick packs, premade pouches or printed rollstock is the better fit.
Custom Sachet Packaging FAQ
Answers to common questions about custom sachet packaging, materials, seal styles, printing and minimum order quantities.
What is custom sachet packaging?
Custom sachet packaging is a small flexible packaging format designed for single-use, portion-controlled or sample products. It can be customized in size, material structure, seal style and printed artwork.
What is the difference between a sachet and a stick pack?
Sachets are generally wider and may be square or rectangular, while stick packs are usually long and narrow. Sachets are commonly used for sauces, powders, cosmetics and samples, while stick packs are especially common for coffee, supplements and drink powders.
What products can be packed in custom sachets?
Typical applications include seasoning powder, coffee, drink mixes, protein powder, supplements, sauces, condiments, shampoo, lotion, skincare products and other single-use products.
What seal styles are available?
Common formats include 3-side seal, 4-side seal and back or fin seal structures. The correct format depends on the product, filling process and packing equipment.
What is the MOQ for custom sachet packaging?
Suitable digital-printing projects can start from around 100 pieces, although 1,000–3,000 pieces is usually a more practical range. Gravure projects commonly start around 10,000 pieces. Exact MOQ depends on sachet size, material structure and production setup.
Should I use digital or gravure printing?
Digital printing is useful for smaller quantities, multiple SKUs and frequent artwork changes. Gravure printing is generally more suitable for stable, repeat and higher-volume orders.
Do I need premade sachets or printed rollstock?
Premade sachets are finished empty packs supplied for filling and final sealing. Printed rollstock is used when an automatic machine forms, fills and seals the sachet from a continuous film roll.
What materials can be used for custom sachet packaging?
Depending on the application, structures may include PET/PE, PET/VMPET/PE, PET/AL/PE, PA/PE and other custom laminates. Transparent high-barrier structures using EVOH can also be evaluated for suitable projects.
Can you make connected strips or chains of sachets?
Connected sachets, perforated strips and multi-sachet chains require project-specific confirmation because feasibility depends on dimensions, seal layout, perforation design and production equipment.
What information is required for a quotation?
Please provide the product type, fill weight or volume, sachet dimensions if known, estimated order quantity, number of SKUs, artwork or reference design and whether you need premade sachets or printed rollstock.
Start Your Custom Sachet Packaging Project
Tell us what you are packing, your target fill weight, expected quantity, preferred sachet size and whether you need premade sachets or rollstock. We can help review the structure, printing method and manufacturing approach.