Sachet Packaging Design Tips: Tear Notch, Round Corner, Side Gusset & Resealable Zippers
If you sell single-serve snacks, drink powders, sauces, coffee, supplement samples, wet wipes, shampoo testers or pet treats, sachet packaging is probably already on your shortlist. The format is compact, cheap to ship and easy for customers to grab on the go.
Most buyers know they want a sachet or flat pouch. What’s tricky is the add-ons — tear notch, round corner, side gusset, resealable zipper — and which ones actually matter for their product. Pick the wrong combination and you either pay for features your product doesn’t need, or ship a pack that’s awkward to open or store.
Here, we’ll show you sachet features, explain what each one does, and guide you on how to match them to your product. DigiPac makes flat pouches in two base formats — Pillow Pack (Center Seal) and 3-Side Seal — and the right starting point is choosing between those before you touch a single add-on.
Why Sachet Packaging Design Details Matter
Small add-ons change how a sachet opens, feels in the hand and performs on the shelf — and the right one depends entirely on your product. A tear notch is about opening. A round corner is about handling and looks. A side gusset is about volume. A resealable zipper is about reuse.
The right feature depends on product type, filling format and how the customer uses the pack.Some features change how the pack opens, some change how it’s handled, and some change its structure.Adding everything is rarely the answer. For example, a single-use ketchup sachet doesn’t need a zipper, and a coffee refill pack doesn’t need rounded corners.
Start by Choosing the Right Flat Pouch Type
Before you choose any feature, choose the base format. A flat pouch is a compact, lay-flat package, and at DigiPac, we offer two: Pillow Pack (Center Seal) and 3-Side Seal. This choice decides which add-ons are even available to you, so it’s the real starting point for any sachet design.
Pillow Pack (Center Seal)
A Pillow Pack, or Center Seal pouch, is back-sealed with a fin seam down the back and closures at the top and bottom. It’s the workhorse format for dry, free-flowing products.
Best for dry goods, powders and single-serve snacks, such as sugar sticks, coffee premix and snack portions.Runs on manual or automated filling lines, so it scales from short runs to high-volume production.A side gusset can be added to this format when you need more capacity than a flat sachet allows.
3-Side Seal
A 3-Side Seal pouch is sealed on three edges with one open end for filling. It’s the slim, clean-faced format you see on cosmetic testers and sauce sachets.
Suits liquids, powders and sample packs.Sleek and slim, so it stores flat and displays cleanly on a shelf or in a hanging strip.Compatible add-ons include a resealable zipper, a spout and a custom die-cut shape.
What Each Sachet Feature Actually Does
The four most common sachet add-ons each solve a different problem: a tear notch helps opening, a round corner improves handling and looks, a side gusset adds volume, and a resealable zipper allows reuse. Here’s how to tell them apart.
Tear notchRound CornerSide GussetResealable Zipper
Tear Notch
A tear notch is a small V-shaped or semi-circular cut on the edge of a pouch that gives the customer a clean, designated point to start tearing. It is the single most useful opening feature for small sachets.
The notch sits just below the seal. It uses tiny cuts in the film to guide the tear straight across the pack, so you don’t need scissors and won’t get a messy rip.It is mainly there to make the pack easier to open. That helps a lot on single-use sachets, sample packs and small pouches.It also works as a safety sign. This means if the notch is still whole, the pack has not been opened yet.On packs with a zipper, a clean tear keeps the zipper in one piece. It’s recommended to put the notch about 6 mm (0.25″) above the zipper.
Round Corner
A round corner replaces the sharp 90-degree corners of a pouch with a smooth, curved edge. It is mainly about comfort and presentation rather than structure.
Softer edges, more comfortable handling and a cleaner, more premium look.Useful for sample packs, personal-care sachets and any consumer-facing format the customer holds.More about feel and finish than function — it won’t add capacity or change how the pack opens.
Side Gusset
A side gusset is a folded panel on each side of the pouch that expands as the pack is filled. Its job is extra capacity.
The folds open out to hold more product. Side gusset panels increase filling volume and let the pack take a fuller, box-like shape.On DigiPac’s flat pouches, the side gusset is offered on the Center Seal / Pillow Pack format.Useful when the pack needs more room than a very flat sachet — bulkier powders, granola or larger portions.Stays compact when empty, then expands once filled.
Resealable Zipper
A resealable zipper is an interlocking closure that lets the customer open and reclose the pouch repeatedly. It exists for products that aren’t finished in one sitting.
Mainly for repeated opening and closing, keeping the contents fresh between uses.For our flat pouches, the zipper is offered in the 3-Side Seal format.Useful when the product is meant to last — multi-serve snacks, supplement powders or pet treats.Pairs naturally with a tear notch: tear once to open, then zip to keep
The four most common sachet add-ons each solve a different problem: a tear notch helps opening, a round corner improves handling and looks, a side gusset adds volume, and a resealable zipper allows reuse. Here’s how to tell them apart.
Tear notchRound CornerSide GussetResealable Zipper
Tear Notch
A tear notch is a small V-shaped or semi-circular cut on the edge of a pouch that gives the customer a clean, designated point to start tearing. It is the single most useful opening feature for small sachets.
The notch sits just below the seal. It uses tiny cuts in the film to guide the tear straight across the pack, so you don’t need scissors and won’t get a messy rip.It is mainly there to make the pack easier to open. That helps a lot on single-use sachets, sample packs and small pouches.It also works as a safety sign. This means if the notch is still whole, the pack has not been opened yet.On packs with a zipper, a clean tear keeps the zipper in one piece. It’s recommended to put the notch about 6 mm (0.25″) above the zipper.
Round Corner
A round corner replaces the sharp 90-degree corners of a pouch with a smooth, curved edge. It is mainly about comfort and presentation rather than structure.
Softer edges, more comfortable handling and a cleaner, more premium look.Useful for sample packs, personal-care sachets and any consumer-facing format the customer holds.More about feel and finish than function — it won’t add capacity or change how the pack opens.
Side Gusset
A side gusset is a folded panel on each side of the pouch that expands as the pack is filled. Its job is extra capacity.
The folds open out to hold more product. Side gusset panels increase filling volume and let the pack take a fuller, box-like shape.On DigiPac’s flat pouches, the side gusset is offered on the Center Seal / Pillow Pack format.Useful when the pack needs more room than a very flat sachet — bulkier powders, granola or larger portions.Stays compact when empty, then expands once filled.
Resealable Zipper
A resealable zipper is an interlocking closure that lets the customer open and reclose the pouch repeatedly. It exists for products that aren’t finished in one sitting.
Mainly for repeated opening and closing, keeping the contents fresh between uses.For our flat pouches, the zipper is offered in the 3-Side Seal format.Useful when the product is meant to last — multi-serve snacks, supplement powders or pet treats.Pairs naturally with a tear notch: tear once to open, then zip to keep
Which Feature Fits Which Product Use Case?
As a rule, dry-fill products start with a Pillow Pack, while samples and multi-use packs start with a 3-Side Seal. Then you layer on the one or two features that match how the product is used.
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Product Type
Best Pouch Direction
Best Features
Dry-fill products (sugar, premix, snacks)
Pillow Pack (Center Seal)
Side gusset if extra volume is needed
Sample / single-use sachets
3-Side Seal
Tear notch
Consumer-facing sachets
3-Side Seal
Round corner + tear notch
Multi-use small packs
3-Side Seal
Resealable zipper
For inspiration, look at how familiar brands handle the format. NESCAFÉ 3 in 1 is sold in single-serve coffee sachets and sticks; stick-pack hydration mixes show how a slim single-serve pack travels well; and beauty brands lean on 3-side-seal sachets for skincare and cosmetic testers. The base format and one well-chosen feature do most of the work.
How DigiPac Can Help
At DigiPac, we make custom flat pouches in both Pillow Pack (Center Seal) and 3-Side Seal formats, and helps you match the right add-ons for each.
Both base formats under one roof: Center Seal for dry-fill products, 3-Side Seal for samples and reusable packs.Guidance on which add-ons pair with which format: side gusset with Center Seal; resealable zipper, spout and custom die-cut with 3-Side Seal.Sustainable material choices, including recyclable, compostable and mono-material structures.Support from design through to delivery, so the artwork, format and features all line up before production.
Conclusion
Good sachet packaging design starts with the base format, not the features. Choose Pillow Pack (Center Seal) for dry-fill products or 3-Side Seal for samples and reusable packs, then add only the features that improve opening (tear notch), handling and looks (round corner), volume (side gusset) or reuse (resealable zipper). Skip the rest — the cleanest pack is the one with exactly the features your product needs and nothing it doesn’t.
Not sure which flat pouch type and sachet features fit your product? Talk to DigiPac and we’ll help you choose the right base format and add-ons before you commit to a run.
Frequently Asked Questions
What is sachet packaging?
Sachet packaging is a small, flat, single-serve or single-use pouch used for products such as coffee, sauces, powders, cosmetic samples and wet wipes. It is compact, lightweight and inexpensive to ship, which makes it popular for on-the-go products and free samples. Most sachets are made as flat pouches in either a Pillow Pack (Center Seal) or 3-Side Seal format.
What is the difference between a Pillow Pack and a 3-Side Seal pouch?
A Pillow Pack (Center Seal) is sealed along the back and across the top and bottom. It suits dry goods, powders and snacks. A 3-Side Seal pouch is sealed on three edges with one open end for filling, and suits liquids, powders and sample packs. The format you choose also decides which add-ons you can use.
Can a sachet have both a tear notch and a resealable zipper?
Yes. On a resealable 3-Side Seal pouch the two features work together: the tear notch gives a clean opening point, and the zipper lets the customer reclose the pack between uses. A tear notch placed just above the zipper keeps the closure intact, so the pouch reseals reliably after the first open.
Which sachet feature is best for sample packs?
For single-use sample packs, a tear notch is the most valuable feature because it makes the sachet easy to open without scissors. A round corner is a useful addition for consumer-facing samples, giving a softer feel and a more premium look. Samples are usually built on the slim 3-Side Seal format.
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Pack quantity and structure — kibble is sold in bigger pack sizes — 2 kg, 7 kg, and 15 kg bags are standard for dog food brands such as Whiskas and Royal Canin. The pouch needs structural strength, a stable base, and material that can carry the weight without splitting.Opening frequency and resealability — treats are opened and closed multiple times daily. A reliable resealable zipper is non-negotiable. Kibble is opened less often per pack, but each opening still has to expose the product to as little air as possible.Product size and storage — kibble is bulky and stored in a cupboard, pantry or pet room. Treats are often kept in a pocket, a treat pouch, or near the leash. The packaging has to fit how it is actually used.
High-barrier laminate for fatty kibble and meaty treats — these go rancid first.UV protection in the outer film if the product will be on bright shop shelves.Sealed seams tested for leakage — the best film fails if the seal does.
Matte finish reads premium and natural; gloss reads playful and energetic.Spot UV or foil on the logo or product name draws the eye in cluttered aisles.Stand-up format gives the front panel real estate at eye level.Photography of the pet, not just the food, performs better at the shelf — show who the product is for.
Larger pouch with a stronger structure — stand-up pouches with reinforced bottom gussets, or block-bottom (quad-seal) bags from 3 kg upwards, hold their shape on shelf and at home.High-barrier multi-layer film — protects against oxygen, moisture and light so kibble stays fresh until the bag is finished.Resealable zipper — essential for repeated daily scooping; pair with a tear notch for clean first opening.Practical handling features — carry handle for 5 kg and 7 kg packs, hang hole or D-cut handle for retail display, and clear feeding-guide panel on the back.
Smaller or medium pouch sizes — 100 g, 200 g and 500 g cover most retail SKUs; very small training-treat pouches under 100 g are common too.Easy-open tear notch — owners often open a treat bag with one hand while holding the dog or the leash.Reliable resealable zipper — treats are opened many times — the zipper has to seal cleanly each time to keep semi-moist or fatty treats from drying out.Attractive print and finish — treats are an impulse buy. Bright colour, premium matte/gloss, and clear product photography drive shelf and online conversion.
Choosing on aesthetics first — a pouch design that wins on Instagram but lets oxygen reach your coffee is a returns problem.Skipping barrier specs for sensitive products — if your product is perishable, a non-barrier pouch ages it on the shelf, not in the customer’s pantry.Adding a spout when the product does not need one — spouts add cost and a failure point — only add them when the product is poured or measured.Forgetting reseal on a multi-use product — a coffee, granola, or pet-treat pouch without a zipper is a one-week pouch.Specifying size and print before confirming production volumes — this locks you into MOQs that do not match your actual sell-through.
