Pouch & Satchet Film Laminations
Sachet packaging is the preferred choice for brands delivering small quantities of product in single-serving or single-use applications. These flat pouches, also called packets, packettes, or sachets, are formed from rollstock film laminations on horizontal or vertical form-fill-seal equipment.
Glenroy custom-engineers pouch film laminations to match your product formulation, shelf life requirements, and filling equipment specifications. Based in the United States since 1965, we manufacture high-quality laminations trusted by consumer goods brands across the global market.
Why Sachet Packaging?
Growing demand for convenience, portion control, and sample-size products has made sachet packaging one of the fastest-growing segments in the packaging industry. Compared to larger formats or plastic bottles, sachets offer distinct advantages:
- Compact footprint that maximizes shelf space and reduces transportation costs
- Single serving precision for dose packaging applications requiring exact quantities
- Extended shelf life through barrier structures that protect product freshness
- Lower material costs using less packaging per unit than rigid containers
- Sampling opportunities that introduce new products to consumers affordably
- Trial-size convenience that meets increasing demand for on-the-go formats
For brands focused on market growth through accessible price points and portability, sachet packaging delivers measurable value.
Sachet Packaging Applications
Glenroy manufactures pouch film laminations for a wide range of industries and product types:
Food Industry: Instant coffee, condiments, seasonings, drink mixes, honey, nut butters, olive oil, and single-serving snacks. Our high-barrier film laminations maintain product quality and freshness.
Personal Care: Shampoo, conditioner, sunscreen, lotion, cosmetic products, serums, and samples. We engineer chemical-resistant structures for personal care products with active ingredients.
Pharmaceutical Industry: Topical medications, ointments, and OTC products. Our quality systems meet the standards required for pharmaceutical applications.
Nutraceuticals: Supplements, powders, drink mixes, and functional ingredients. Barrier protection preserves potency through the product lifecycle.
Household Products: Cleaners, detergents, and industrial applications requiring puncture-resistant, chemical-compatible structures.​
Custom-Engineered Film Structures
Every product has unique requirements. Our engineering team works directly with you to develop pouch film laminations with the specific properties your application demands:
- Oxygen, moisture, or light barriers using aluminum foil or metalized films
- Chemical resistance for aggressive product formulations
- Puncture and tear resistance for distribution durability
- Easy-open features, including tear notches, laser-scoring, Tear-Anywhere™ film, and peelable seals
- Low coefficient of friction for optimal equipment performance
- Heat seal compatibility with your filling equipment
We perform product/package compatibility testing to simulate how your formulation interacts with various film structures before production. This eliminates surprises and ensures product quality throughout the entire shelf life.
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Sustainable Sachet Options
Environmental concerns are driving innovative solutions in the sachet packaging market. Glenroy offers options that help brands meet sustainability goals:
- Recyclable film laminations compatible with store drop-off recycling
- PCR film laminations incorporating post-consumer recycled content
- Source-reduced structures that minimize material while maintaining performance
Learn more about our sustainable flexible packaging initiatives
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Why Brands Choose Glenroy
Contract packagers and consumer goods companies across the United States choose Glenroy for sachet packaging because our laminations run consistently on filling equipment. That consistency translates to lower scrap rates, faster line speeds, and better margins for your operation.
Our capabilities include:
- Custom-engineered laminations designed for your specific product
- Adhesive and extrusion laminating for multi-layer structures
- Award-winning flexographic printing up to 10 colors
- Custom slitting and finishing services, including laser-scoring, to match your equipment specifications
- Dependable lead times and responsive technical support
Looking for stick packaging? We also manufacture film laminations for stick packs and narrow-web applications.
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Frequently Asked Questions
What is sachet packaging?
Sachet packaging refers to small, flat pouches formed from flexible film laminations, typically used for single-serving or single-use applications. Sachets are created on HFFS or VFFS filling equipment.
What products work best in sachets?
Sachets are ideal for instant coffee, condiments, personal care products, pharmaceutical applications, supplements, and any product requiring portion control or small quantities.
What's the difference between sachets and stand-up pouches?
Sachets are flat pouches formed on filling equipment from rollstock. Stand-up pouches are premade pouches with a bottom gusset that allows them to stand upright on shelves.
What barrier options are available?
We offer aluminum foil, metalized films, EVOH, and other high-barrier materials depending on your oxygen, moisture, and light protection requirements.
What are the minimum order quantities?
Quantities vary based on structure complexity and print requirements. Contact our team to discuss your project specifications.
Can sachets be recycled?
Yes. We offer recyclable sachet film structures as part of our commitment to addressing environmental concerns in flexible packaging.