Fast Food Ketchup Sachet with Tear Notch | Single-Use Condiment Pack for Fries, Burgers & Takeaways – Custom Printed Laminated Packaging Also Available for Honey, Juice & Puree
The Ultimate Guide to Flexible Packaging – From Fast Food Ketchup Sachets to Premium Honey Spout Pouches
Welcome to Your One-Stop Packaging Partner
Think about the last time you enjoyed a meal from McDonald's, Burger King, or your favorite local takeaway.
You unwrapped your burger. You grabbed a small ketchup sachet. You found the tear notch. You pulled it open. You squeezed the perfect amount onto your fries. And you enjoyed every bite.
That small sachet is a masterpiece of packaging engineering.
It is lightweight yet strong. It keeps ketchup fresh for months. It opens cleanly with one motion. It dispenses the exact right amount. And it costs pennies to produce.
Now imagine scaling that same technology up.
Imagine a stand-up spout pouch for honey. Same multi-layer film. Same barrier protection. Same quality printing. But with a resealable cap, a squeeze-to-empty design, and enough capacity for a whole family.
Our factory does both.
We produce millions of fast food ketchup sachets with tear notches for quick-service restaurants, takeaway shops, and food service distributors.
And we produce thousands of premium honey spout pouches for honey brands, juice manufacturers, and specialty food producers.
This guide explains everything you need to know about both product lines – and how we can help your business grow.
PART ONE: FAST FOOD KETCHUP SACHETS – THE BACKBONE OF FOOD SERVICE
1.1 What Is a Fast Food Ketchup Sachet?
A ketchup sachet is a small, hermetically sealed flexible packet designed for single-use portions of condiments. The tear notch is a precision cut in the sealed edge that allows the user to open the packet cleanly without scissors, teeth, or frustration.
Key Features at a Glance:
| Feature | Description |
|---|---|
| Size | Typically 5ml to 30ml |
| Shape | Rectangular with heat-sealed edges |
| Opening mechanism | Tear notch (V-notch, laser score, or side notch) |
| Material | Multi-layer laminated film (2 or 3 layers) |
| Printing | Full custom branding, up to 10 colors |
| Shelf life | 6-18 months depending on film |
1.2 Why Fast Food Chains Rely on Sachets
| Benefit | Why It Matters |
|---|---|
| Portion control | Every customer gets exactly the same amount |
| Zero waste | No pumps, no spills, no refilling |
| Hygiene | Sealed, single-use, no contamination risk |
| Efficiency | No cleaning, no maintenance, no training |
| Branding | Every packet carries your logo |
| Shelf stability | Room temperature storage, long life |
| Cost | Low per-unit cost at scale |
1.3 The Tear Notch: Small Detail, Huge Impact
The tear notch is the most important feature on a condiment sachet. Without it, customers would struggle to open the packet.
Types of Tear Notches:
| Type | How It Works | Best For |
|---|---|---|
| V-notch | V-shaped cut in the seal edge | Standard ketchup, mustard, mayo |
| Laser score | Precision thinning of the film | Premium sachets, cleanest tear |
| Side notch | Notch on the long edge | Wider packets, easy gripping |
| Double notch | Two notches for larger packets | Extra-large portions |
Why Easy-Tear Matters:
-
Speed: One motion opening
-
Cleanliness: No biting, no mess
-
Safety: No jagged edges
-
Consistency: Every packet tears the same way
-
Customer satisfaction: Frustration-free experience
1.4 Film Structure for Ketchup Sachets
Standard Structure (2-Layer) – Cost-Effective:
| Layer | Material | Thickness | Job |
|---|---|---|---|
| Outer | PET (Polyester) | 12µm | Holds printing, provides strength, resists heat |
| Inner | PE (Polyethylene) | 40-60µm | Creates seal, touches food, blocks moisture |
-
Oxygen barrier: ≤5.0 cc/m²/day
-
Moisture barrier: ≤3.0 g/m²/day
-
Shelf life: 6-12 months
-
Best for: Ketchup, mustard, mayonnaise, barbecue sauce, soy sauce
Premium Structure (3-Layer) – Extended Shelf Life:
| Layer | Material | Thickness | Job |
|---|---|---|---|
| Outer | PET | 12µm | Printing, durability |
| Barrier | VMPET (Metallized) | 12µm | Blocks oxygen, moisture, and light |
| Inner | PE | 50-70µm | Hermetic seal, food contact |
-
Oxygen barrier: ≤1.5 cc/m²/day
-
Moisture barrier: ≤1.0 g/m²/day
-
Shelf life: 12-18 months
-
Best for: Premium condiments, natural ingredients, preservative-free products
1.5 Standard Sizes for Ketchup Sachets
| Volume | Dimensions (approx) | Best For |
|---|---|---|
| 5ml | 30 x 50mm | Sample size, ultra-small portion |
| 8ml | 33 x 55mm | Small condiment portion |
| 9ml | 35 x 60mm | Standard ketchup (McDonald's style) |
| 10ml | 38 x 65mm | Most common condiment size |
| 12ml | 40 x 65mm | Ketchup, honey, mustard |
| 15ml | 40 x 70mm | Honey, syrup, larger sauce |
| 20ml | 45 x 75mm | Premium sauce, dressing |
| 25ml | 50 x 80mm | Extra-large portion |
| 30ml | 50 x 85mm | Honey, puree, single-serve juice |
Custom sizes available. Contact us for your specific needs.
1.6 Custom Printing for Sachets
What to Print on Your Sachets:
| Element | Purpose |
|---|---|
| Brand name and logo | Brand recognition |
| Product name | "Ketchup," "Honey," "Mustard" |
| Tear arrow | Shows customers where to open |
| "Easy tear" text | Reinforces usability |
| Expiration date | Food safety (printed or inkjet) |
| Barcode | Scanning at point of sale |
| Nutritional information | Legal requirement in many markets |
| Ingredients list | Regulatory compliance |
Printing Methods:
| Method | Best Volume | Colors | Quality | Tooling Cost |
|---|---|---|---|---|
| Rotogravure | 500,000+ sachets | Up to 10 | Photorealistic | Higher |
| Flexography | 100,000-500,000 | Up to 8 | Very good | Lower |
1.7 Applications Beyond Ketchup
While ketchup is the most common, our sachets work for many products:
| Product | Typical Size | Film Recommendation | Special Consideration |
|---|---|---|---|
| Tomato ketchup | 9-10ml | 2-layer PET/PE | Standard |
| Yellow mustard | 8-10ml | 2-layer PET/PE | Standard |
| Mayonnaise | 10-15ml | 3-layer (oil resistance) | Oil barrier needed |
| Honey | 10-20ml | 3-layer (moisture barrier) | Prevent crystallization |
| Maple syrup | 15-25ml | 3-layer (hot-fill) | Heat resistance |
| Soy sauce | 5-10ml | 2-layer PET/PE | Standard |
| Hot sauce | 5-10ml | 2-layer (acid resistance) | Acid-resistant sealant |
| Barbecue sauce | 15-20ml | 2-layer or 3-layer | Standard |
| Salad dressing | 15-30ml | 3-layer (oil resistance) | Oil barrier needed |
| Juice concentrate | 10-20ml | 3-layer (oxygen barrier) | Prevent oxidation |
PART TWO: HONEY SPOUT POUCHES – SCALING UP FOR RETAIL & FAMILY USE
Now let's go bigger.
The same factory that produces millions of tiny ketchup sachets also produces premium stand-up spout pouches for honey, juice concentrates, fruit purees, and other liquid products.
Think of it as the big brother of the sachet. Same film technology. Same quality standards. But with a spout, a cap, and enough capacity for a whole family.
2.1 Why Honey Brands Are Switching to Spout Pouches
The honey packaging market is changing. Glass jars are losing ground to flexible spout pouches. Here is why:
| Problem with Glass Jars | Solution with Spout Pouch | Impact |
|---|---|---|
| Heavy (220g for 500ml) | Lightweight (12g for 500ml) | 94% less weight – lower shipping cost |
| Breakable | Unbreakable | Zero breakage – no product loss |
| Honey crystallizes | Superior moisture barrier | 2x longer shelf life |
| Sticky, messy dispensing | No-drip flip-top cap | Clean hands, happy customers |
| Hard to get last honey out | Squeeze-to-empty design | Zero waste, full use |
| Bulky storage | Collapsible as emptied | Saves space in cupboards |
| Small label area | Full-surface printing | More branding, better visibility |
2.2 Honey Spout Pouch Sizes
| Volume | Dimensions (approx) | Best For |
|---|---|---|
| 50ml | 85 x 110mm | Sample size, hotel amenities, travel |
| 100ml | 100 x 140mm | Single-serve, gift boxes, trial packs |
| 150ml | 110 x 160mm | Small household, specialty honey |
| 200ml | 120 x 175mm | Everyday retail |
| 250ml | 130 x 190mm | Most popular size |
| 300ml | 140 x 200mm | Family size |
| 500ml | 160 x 235mm | Bulk, food service, value pack |
| 1000ml | 190 x 290mm | Commercial, professional kitchens |
Custom sizes available. Just ask.
2.3 Film Structures for Honey Spout Pouches
Standard Honey Structure (3-Layer) – 12-18 Months Shelf Life:
| Layer | Material | Thickness | Job |
|---|---|---|---|
| Outer | PET | 12µm | Print surface, gloss, scuff resistance |
| Barrier | VMPET | 12µm | Blocks oxygen, moisture, and light |
| Inner | PE | 70-100µm | Hermetic seal, food contact |
-
Oxygen barrier: ≤1.5 cc/m²/day
-
Moisture barrier: ≤1.0 g/m²/day
-
Best for: Standard honey, regional distribution
Premium Honey Structure (4-Layer) – 18-24+ Months Shelf Life:
| Layer | Material | Thickness | Job |
|---|---|---|---|
| Outer | PET | 12µm | Print, durability, scuff resistance |
| Barrier | AL Foil | 7-9µm | Absolute oxygen, moisture, UV barrier |
| Strength | PA Nylon | 15µm | Puncture resistance, tear strength |
| Inner | PE | 80-120µm | Premium seal, food contact |
-
Oxygen barrier: ≤0.2 cc/m²/day
-
Moisture barrier: ≤0.2 g/m²/day
-
Best for: Premium honey, export markets, long shelf life
2.4 Cap Options for Honey
Flip-Top Cap – Most Popular for Honey
| Feature | Detail |
|---|---|
| Orifice sizes | 8mm, 10mm, 12mm |
| Material | Polypropylene, food-grade |
| Operation | Snap open, snap closed |
| Special feature | Self-cleaning nozzle – honey pulls back inside |
| Best viscosity | 1,000-15,000 cP |
| Tamper evidence | Optional breakable bridges |
Screw Cap – Best for Thick Honey
| Feature | Detail |
|---|---|
| Orifice sizes | 12mm, 15mm, 20mm |
| Material | HDPE or PP |
| Operation | Twist on, twist off |
| Special feature | Induction liner for freshness |
| Best viscosity | 5,000-50,000+ cP |
| Tamper evidence | Induction seal standard |
Sports Cap – Best for On-the-Go
| Feature | Detail |
|---|---|
| Orifice sizes | 6mm, 8mm |
| Material | PP |
| Operation | Push to open, pull to close |
| Special feature | Silicone valve – zero leaks in bags |
| Best viscosity | 1,000-15,000 cP |
| Tamper evidence | Breakable band |
2.5 Custom Printing for Honey Spout Pouches
| Feature | Capability |
|---|---|
| Printing methods | Rotogravure (high volume) or Flexography (medium volume) |
| Maximum colors | Up to 10 |
| Finishes | Gloss, matte, metallic, soft-touch |
| Special effects | Spot varnish, cold foil, clear window |
| Quality | Photorealistic (gravure) or very good (flexo) |
Design Tips for Honey Brands:
-
Use warm colors: Gold, amber, orange, honey brown
-
Show the product: Drizzle shots look delicious
-
Add a clear window: Let customers see your beautiful honey
-
Highlight claims: "Raw," "Unfiltered," "Organic," "100% Pure"
-
Tell your story: Origin information builds trust
-
Add a QR code: Link to recipes, beekeeping stories, or authentication
No artwork? Send us your logo and brand colors. Our design team will create professional print-ready files.
PART THREE: THE TECHNOLOGY THAT CONNECTS THEM BOTH
Whether we are making 10,000 ketchup sachets or 50,000 honey spout pouches, the underlying technology is the same.
3.1 Multi-Layer Lamination Explained
Single-layer plastic cannot do everything well. A film that prints beautifully may not seal properly. A film that seals well may not block oxygen.
Multi-layer lamination solves this by combining complementary materials into a single, unified film.
For Ketchup Sachets (2-Layer):
PET (printing + strength) + PE (sealing + moisture barrier)
For Honey Spout Pouches (3 or 4-Layer):
PET (printing) + VMPET/AL (barrier) + PA (strength) + PE (sealing)
3.2 Barrier Performance Comparison
| Product | Film Layers | OTR (oxygen) | MVTR (moisture) | Shelf Life |
|---|---|---|---|---|
| Ketchup sachet (standard) | 2 | ≤5.0 | ≤3.0 | 6-12 months |
| Ketchup sachet (premium) | 3 | ≤1.5 | ≤1.0 | 12-18 months |
| Honey spout pouch (standard) | 3 | ≤1.5 | ≤1.0 | 12-18 months |
| Honey spout pouch (premium) | 4 | ≤0.2 | ≤0.2 | 18-24+ months |
3.3 Printing Quality Across Both Lines
| Feature | Ketchup Sachets | Honey Spout Pouches |
|---|---|---|
| Maximum colors | 10 | 10 |
| Registration tolerance | ±0.5mm | ±0.5mm |
| Finish options | Gloss, matte | Gloss, matte, metallic |
| Clear window | Not typical | Yes |
PART FOUR: QUALITY ASSURANCE – SAME STANDARDS FOR ALL PRODUCTS
Whether you order 100,000 sachets or 50,000 pouches, our quality standards never change.
4.1 Testing for Ketchup Sachets
| Test | Method | Acceptance Standard |
|---|---|---|
| Seal strength | Tensile pull | >20 N/15mm |
| Burst resistance | Internal pressure | No failure at 25 PSI |
| Vacuum leak | Chamber test | Zero bubbles at 20 in Hg, 60 sec |
| Tear notch function | Manual pull | Clean tear, no jagged edges |
| Print quality | Visual inspection | Matches approved sample |
4.2 Testing for Honey Spout Pouches
| Test | Method | Acceptance Standard |
|---|---|---|
| Seal strength | Tensile pull | >25 N/15mm (3-layer), >35 N/15mm (4-layer) |
| Burst resistance | Internal pressure | No failure at 30 PSI |
| Vacuum leak | Chamber test | Zero leaks at 25 in Hg, 60 sec |
| Spout pull force | Force test | >80 N |
| Drop test | 1.5m fall | No seal separation |
| Print quality | Visual + measurement | Within ±0.5mm of master |
4.3 Certifications
| Certification | Ketchup Sachets | Honey Spout Pouches |
|---|---|---|
| ISO 9001:2015 | ✓ | ✓ |
| FDA food contact | ✓ | ✓ |
| EU 10/2011 | ✓ | ✓ |
| BPA-free | ✓ | ✓ |
| Halal | Available | Available |
| Kosher | Available | Available |
PART FIVE: PRODUCTION AND ORDERING
5.1 Lead Times
| Product | Sample Lead Time | Production Lead Time |
|---|---|---|
| Ketchup sachets (unprinted) | 7-10 days | 20-30 days |
| Ketchup sachets (printed) | 15-20 days | 25-35 days |
| Honey spout pouches (unprinted) | 10-15 days | 25-35 days |
| Honey spout pouches (printed) | 20-25 days | 30-45 days |
5.2 Minimum Order Quantities
| Product | Minimum |
|---|---|
| Ketchup sachet sample (unprinted) | 10,000 pieces |
| Ketchup sachet sample (printed) | 50,000 pieces |
| Ketchup sachet production | 100,000 pieces |
| Honey spout pouch sample (unprinted) | 1,000 pieces |
| Honey spout pouch sample (printed) | 5,000 pieces |
| Honey spout pouch production | 30,000 pieces |
Smaller quantities may be available for startups. Contact us to discuss.
5.3 Shipping
| Parameter | Detail |
|---|---|
| FOB ports | Ningbo, Shanghai, Shenzhen |
| Incoterms | EXW, FOB, CIF, CFR |
| Sachets per pallet | 500,000+ (depending on size) |
| Spout pouches per 20FT | ~22 pallets |
PART SIX: FREQUENTLY ASKED QUESTIONS
About Ketchup Sachets
Q: What is the typical shelf life for ketchup in your sachets?
A: 6-12 months with standard 2-layer film. 12-18 months with premium 3-layer VMPET film.
Q: Can you match the exact size of McDonald's or KFC ketchup packets?
A: Yes. We can match standard industry sizes. We cannot copy trademarks.
Q: How does the tear notch work?
A: The notch creates a stress point. When pulled, the film tears cleanly along a straight line.
Q: Can the tear notch be on the side instead of the top?
A: Yes. We can place the notch on any edge per your specification.
About Honey Spout Pouches
Q: How long will honey stay fresh in your spout pouches?
A: Standard 3-layer: 12-18 months. Premium 4-layer with aluminum foil: 18-24+ months.
Q: Does the flip-top cap really prevent drips?
A: Yes. The self-cleaning nozzle design pulls honey back inside when the cap closes.
Q: Can I use these pouches for hot-fill honey?
A: Yes. With CPP sealant layer, pouches withstand filling up to 95°C (203°F).
Q: Are the materials safe for honey?
A: Yes. All food-contact materials are FDA-compliant and BPA-free.
General Questions
Q: Do you provide samples? – Yes, strongly recommended.
Q: Can you help with artwork? – Yes, send your logo and colors.
Q: What are your payment terms? – 50% deposit, 50% against bill of lading.
Q: Do you ship worldwide? – Yes, to all major markets.
PART SEVEN: HOW TO ORDER
Step 1 – Contact Us
Send us:
-
Product type (ketchup, honey, puree, etc.)
-
Format (sachet or spout pouch)
-
Desired size (ml)
-
Target shelf life
-
Estimated annual quantity
-
Cap preference (for spout pouches)
Step 2 – Receive Custom Quote
Within 24 hours, we provide:
-
Recommended film structure with barrier data
-
Tear notch or cap options
-
Printing specifications
-
Sample costs and lead time
-
Production pricing (FOB)
Step 3 – Approve Samples
We produce empty samples with your printing. You test. You approve.
Step 4 – Production and Delivery
We manufacture. We test. We ship. You succeed.
CONCLUSION: Your Complete Packaging Partner
From the smallest ketchup sachet for fast food fries to the largest honey spout pouch for family kitchens, our factory delivers.
We produce:
-
Easy-tear ketchup sachets for quick-service restaurants
-
Custom condiment packets for takeaways and food service
-
Premium honey spout pouches with no-drip caps
-
Stand-up pouches for juices, purees, and liquid products
We serve:
-
Fast food chains and QSRs
-
Food service distributors and caterers
-
Honey producers and honey packers
-
Juice and puree manufacturers
-
Specialty food brands worldwide
We ship:
-
Worldwide, to your door
Ready to Start?
Contact us today.
Get in Touch
Have questions about our products or want to discuss a custom order? Our team is ready to help you.