Potential advantages
Portion control; compact transport; high-volume production potential; low material per individual pack in some applications.
Flexible Packaging · Technical GuideSachets & Three-Side-Seal Pouches
Sachets & Three-Side-Seal Pouches
Explained.
Compact sealed packs formed from flexible web or sheet material for single-use or measured portions. A three-side-seal pouch is made by sealing three edges around a product cavity, with the remaining edge used for filling and then sealed. “Sachet” describes a broad small-pack format rather than one single construction. Sachets can be made from one web folded over or two webs, depending on the converting line.
First, recognise the pack
What this format looks like
A sachet is a compact, mostly flat pack formed by sealing flexible material around a measured portion.
- Identify the overall silhouette before choosing the material.
- Check how the package stands, opens, fills and seals.
- Keep important text and logos clear of folds, fitments and seal zones.
The illustration is a visual starting point; actual seal layout and whether the pouch uses three- or four-side sealing depend on the converter’s construction. This is a conceptual visual, not a production sample or approved dieline.
Schematic only; not to scale. Final material construction, dimensions, seals, closures and print zones must come from the selected packaging converter.
01 / Anatomy & construction
What is this format?
A three-side-seal pouch is made by sealing three edges around a product cavity, with the remaining edge used for filling and then sealed. “Sachet” describes a broad small-pack format rather than one single construction. Sachets can be made from one web folded over or two webs, depending on the converting line.
Key components
- Front and back webs
One or two pieces of flexible material create the pack faces. - Three perimeter seals
Seals enclose the product cavity; seal width and consistency are key performance factors. - Fill opening
Left accessible during filling and sealed after the correct quantity is introduced. - Tear notch / easy-open feature
Optional feature positioned to allow opening without cutting through critical information. - Print repeat
On roll-fed production, artwork repeats at a defined pitch and must align with the machine registration system.
Design principle: build the artwork around the real pack construction, not the other way around. Folds, seals, fitments and machine requirements can change the printable area.
02 / Materials & structure
What is it made from?
Common component roles are described below for learning. They are not a recommended bill of materials for every product or supplier.
| Component / layer | Typical role and specification questions |
|---|---|
| Print layer | May be surface printed or reverse printed depending on construction and process. |
| Barrier / support layer | Chosen according to product sensitivity and converting needs. |
| Heat-seal layer | Allows the perimeter to seal under validated time, temperature and pressure conditions. |
Important: a pack’s performance depends on the complete converted structure, including seams, folds, seals, fitments, thickness, process settings and storage conditions. Ask the converter for supporting technical data and product-specific validation.
03 / Applications & trade-offsPROTECTION PRODUCTION USE & DISTRIBUTION
Where is it used?
Seasonings, sauces, condiments, personal-care samples, powders, single-use portions and small-format promotional packs.
Trade-offs to consider
Limited reclosure; small space for legible copy; difficult opening if notch and material are poorly matched; very dependent on filling-line settings.
Define the product’s sensitivity to moisture, oxygen, light, aroma, contamination, impact or leakage where relevant.
Confirm filling equipment, speed, sealing method, machine compatibility, pack orientation and expected production volume.
Consider transport, stacking, shelf presentation, opening, carrying, reclosure and local end-of-life realities.
04 / Artwork & prepress
Designing for the real pack
Prioritise the product name, variant, mandatory information and brand mark. On very small packs, confirm minimum type size and barcode feasibility before finalising the layout.
Pre-production checklist
- Confirm finished sachet size and fill quantity.
- Get the repeat length, web width, print direction and registration details.
- Ask where the cut, seal and tear notch will sit.
- Check small typography and barcode feasibility at actual size.
- Test opening behaviour and seal integrity with the converter.
Artwork handover: request the approved dieline or panel drawing, print specifications, colour guidance, technical layer instructions and proofing procedure from the supplier. Never assume a generic template is production-ready.
Read the full artwork & prepress guide ↗05 / Common questions
Frequently asked questions
Are sachets always single-use?
Many are, but format and usage depend on the product and closure. Most simple three-side-seal sachets are not designed for reclosure.
Why is repeat length important?
It defines how the artwork repeats along the web and must match the converter’s cutting and registration system.
Can every sachet include a barcode?
Not always. Available space, print quality and scanning requirements need to be checked early.
This guide is educational and is not a substitute for packaging engineering, product testing, food-contact review or current regulatory advice. Confirm applicable Kenyan and destination-market requirements with the responsible product owner and qualified specialists.
Need packaging artwork for this format?
Share the product, target pack size, filling method, reference images and converter specification. Briandcas can help scope the design and prepress requirements.