One of the first decisions every powder supplement brand makes — and one of the most consequential — is packaging format. Sachet, zipper pouch, or gusset bag each represent fundamentally different positioning decisions, not just packaging choices.
The wrong format at the wrong stage costs you money. The right format at the right stage can define your brand.
What Is a Sachet?
A sachet is a sealed, single-use packet — typically a four-sided heat seal made from roll stock film. Sachets range from small (3"x3") to fairly large (5.5"x9" tall) and are designed to be torn open and used entirely at once. They're the dominant format for single-serve supplements, on-the-go food products, and travel packs.
Overgang runs roll stock sachets from 3"x3" minimum to 5.5"x9" maximum with fill weights from 9g to 90g depending on powder density.
Sachets are best for:
- Single-serve supplements (pre-workout, electrolytes, protein)
- On-the-go food formats (drink mixes, meal replacement sticks)
- Trial packs and sampling programs
- DTC subscription boxes
- Impulse retail and convenience channel
- Amazon single-serve listings
Sachets are not ideal for:
- Products customers use multiple times before finishing
- Fills over 90g
- Brands that want a prominent retail shelf presence
What Is a Zipper Pouch?
A zipper pouch (also called a stand-up pouch or resealable pouch) has a zipper closure at the top, allowing the customer to open and reseal multiple times. They stand upright on a retail shelf, creating significant visual real estate. Most multi-serving supplement products — protein tubs excluded — ship in zipper pouch format.
Overgang runs zipper pouches up to 5.5" wide by 9" tall.
Zipper pouches are best for:
- Multi-serving supplements (collagen, greens, creatine)
- Retail shelf presence
- Brands that want premium packaging feel
- Products with 15–30 serving counts
- DTC brands where the unboxing experience matters
Zipper pouches are not ideal for:
- First-run validation (higher cost per unit, more expensive to change)
- Products under 15g fill weight
- Sampling and trial applications
What Is a Gusset Bag?
A gusset bag has expandable sides (the gusset) that allow it to hold significantly more volume than a flat sachet or standard zipper pouch. They're used for larger fill weights and often for products going into bulk or club formats. Fill weights up to 500g are possible depending on pouch width.
Overgang can run gusset pouches — pricing is quoted on a project basis because run parameters vary significantly by width and fill weight.
Gusset bags are best for:
- High-volume fills (50g–500g)
- Club store formats (Costco-style)
- Value sizes and bulk supplements
- Brands with established velocity who need larger formats
The Cost Difference Between Formats
Film cost, machine time, and fill rate all vary by format. Here's a rough comparison:
| Format | Film Cost (relative) | Fill Rate | Min Fill | Max Fill |
|---|---|---|---|---|
| Roll stock sachet | Lowest | Fastest | 9g | 90g |
| Zipper pouch | Medium | Medium | 15g | ~200g |
| Gusset bag | Highest | Slower | 50g | 500g+ |
The Format Decision Framework
Here's the simplest way to think about it:
- If your product is single-serve and under 30g: sachet. No debate.
- If your product is multi-serve and going to retail: zipper pouch.
- If you're in the 50g–500g range: gusset bag, quoted project basis.
- If you're not sure and it's your first run: start with sachets. They're the cheapest to produce, the easiest to change, and the least risky format to validate your concept on.
The first-run rule
For any brand that hasn't proven product-market fit, we recommend starting with sachets or the simplest possible format — even if your long-term vision is a premium zipper pouch. Validate your formula and your channel first. Then upgrade the packaging once you know what's working.
What to Ask Your Film Supplier
Regardless of format, your film supplier needs to give you die lines — the template files your designer uses to create artwork that fits your specific pouch dimensions. Key questions to ask:
- What are the exact die line dimensions for my pouch size?
- What material is recommended for my product type (moisture barrier, oxygen barrier)?
- What is your minimum film order quantity?
- What is the lead time from artwork approval to delivery? (Budget 10–12 business days)
Overgang can recommend film suppliers we trust. We don't supply film ourselves — you source it directly — but we'll confirm your roll stock is compatible with our machine before your run date.