Ketchup Portion Pack with Tear Notch | Single-Serve Condiment Sachet for Fast Food, Takeout & Catering
Custom printed laminated packaging for liquids, juice & puree. Also available with spout & cap.
The Complete Guide to Portion Pack Packaging
From fast food ketchup to premium honey pouches - discover the engineering behind these essential packaging solutions.
Introduction: The Little Packet That Does Big Business
Walk into any McDonald's, Burger King, or KFC around the world and you'll find small packets of ketchup on every tray. These unassuming packets are marvels of packaging engineering - keeping ketchup fresh for months, surviving shipping across oceans, opening with a gentle pull, and dispensing exactly the right amount.
Our factory produces these packets and much more. The same technology that keeps fast food ketchup fresh can also package honey, juices, purees, and other liquid products. We can add spouts and caps for larger formats, custom print your brand in up to 10 colors, and engineer films to block oxygen, moisture, and light.
What Is a Portion Pack with Tear Notch?
Definition
A portion pack (also called a sachet or condiment packet) is a small, flexible pouch designed for single-use portions of liquid or semi-liquid products. The tear notch is a small cut or indentation on the edge of the packet that allows easy opening without tools.
Key Features
| Feature |
What It Does |
Why It Matters |
| Tear notch |
Creates a weak point for easy opening |
One-motion opening, no tools needed |
| Multi-layer film |
Blocks oxygen, moisture, light |
Extends shelf life |
| Heat seal |
Hermetically closes the packet |
No leaks, no contamination |
| Custom printing |
Displays brand, product info, instructions |
Marketing and usability |
Common Sizes
| Volume |
Dimensions (typical) |
Best For |
| 5ml |
30 x 50mm |
Sample, ultra-small portion |
| 9ml |
35 x 60mm |
Standard ketchup packet (McDonald's size) |
| 10ml |
38 x 65mm |
Common condiment size |
| 15ml |
40 x 70mm |
Larger portion, honey, syrup |
| 20ml |
45 x 75mm |
Premium condiments, dressings |
| 30ml |
50 x 85mm |
Honey, puree, single-serve juice |
Custom sizes available
The Tear Notch - Small Detail, Big Impact
What Is a Tear Notch?
A tear notch is a small cut or V-shaped indentation on the sealed edge that creates a stress concentration point. When pulled from the notch, the film tears cleanly along a straight line.
Types of Tear Notches
| Type |
Description |
Best For |
| V-notch |
V-shaped cut into the seal edge |
Most common, easy to manufacture |
| Laser score |
Precise thinning of the film |
Premium packs, clean tear |
| Side notch |
Notch on the side edge |
Wide packs, easy gripping |
| Corner notch |
Notch at the corner |
Small packs, intuitive opening |
Why Tear Notch Matters for Fast Food
- Speed: Customers open packets in seconds, not minutes
- Cleanliness: No need to bite packets open
- Consistency: Every packet tears the same way
- Safety: No sharp edges, no flying plastic pieces
Film Technology for Portion Packs
Basic Structure
Most portion packs use 2-layer or 3-layer laminates for optimal performance and protection.
Standard 2-Layer Structure (for ketchup, condiments)
| Layer |
Material |
Thickness |
Function |
| Outer |
PET |
12µm |
Print, strength, heat resistance |
| Inner |
PE or PP |
40-60µm |
Seal, food contact, moisture barrier |
Shelf life: 6-12 months
Best for: Ketchup, mustard, mayonnaise, soy sauce
Premium 3-Layer Structure (for longer shelf life, sensitive products)
| Layer |
Material |
Thickness |
Function |
| Outer |
PET |
12µm |
Print, durability |
| Barrier |
VMPET or EVOH |
12µm |
Oxygen and moisture barrier |
| Inner |
PE |
50-70µm |
Seal, food contact |
Shelf life: 12-18 months
Best for: Honey, juice concentrates, premium condiments
Material Options for Portion Packs
| Material |
Property |
Application |
| PET |
Strong, clear, printable |
Outer layer for all packs |
| VMPET |
Metallized, high barrier |
Oxygen-sensitive products |
| PE |
Seals well, flexible |
Inner layer, standard |
| PP |
Heat resistant, clear |
Inner layer for hot-fill |
| AL Foil |
Absolute barrier |
Premium, long shelf life |
| PA (Nylon) |
Puncture resistant |
Products with sharp particles |
Barrier Performance
| Product |
Recommended OTR |
Recommended MVTR |
| Ketchup |
≤5.0 cc/m²/day |
≤3.0 g/m²/day |
| Honey |
≤1.5 cc/m²/day |
≤1.0 g/m²/day |
| Juice concentrate |
≤1.0 cc/m²/day |
≤1.0 g/m²/day |
| Premium condiments |
≤0.5 cc/m²/day |
≤0.5 g/m²/day |
From Portion Packs to Spout Pouches
The same factory that makes small ketchup portion packs can also produce larger stand-up spout pouches for honey, purees, juices, and liquid products. Same technology, same quality, different format.
Product Evolution
| Format |
Volume |
Best For |
Key Feature |
| Portion pack |
5-30ml |
Single-serve, fast food |
Tear notch |
| Small spout pouch |
50-150ml |
Travel, trial size |
Resealable cap |
| Standard spout pouch |
200-500ml |
Household, retail |
Stand-up, squeeze |
| Large spout pouch |
500-1000ml |
Bulk, food service |
Big volume, easy pour |
Honey in Spout Pouches - A Growing Market
Honey is one of the fastest-growing categories for spout pouch packaging due to significant advantages over traditional glass jars.
| Problem with Glass Jars |
Solution with Spout Pouch |
| Honey crystallizes |
Better moisture barrier |
| Sticky, messy dispensing |
No-drip flip-top cap |
| Hard to get last honey out |
Squeeze-to-empty design |
| Heavy, breakable |
Lightweight, unbreakable |
| Bulky storage |
Collapsible as emptied |
Spout Pouch Film Structures for Honey
Recommended 3-Layer Structure (PET/VMPET/PE):
| Layer |
Material |
Function |
| Outer |
PET |
Print, gloss, scuff resistance |
| Barrier |
VMPET |
Oxygen, moisture, light barrier |
| Inner |
PE |
Seal, food contact |
Shelf life: 12-18 months
Best for: Standard honey products
Premium 4-Layer Structure (PET/AL/PA/PE):
| Layer |
Material |
Function |
| Outer |
PET |
Print, durability |
| Barrier |
AL Foil |
Absolute oxygen/moisture/UV barrier |
| Strength |
PA Nylon |
Puncture resistance |
| Inner |
PE |
Seal, food contact |
Shelf life: 18-24+ months
Best for: Premium honey, export, long shelf life
Cap Options for Honey Spout Pouches
When moving from portion packs to spout pouches, the cap becomes critical for functionality and user experience.
Flip-Top Cap (Most Popular for Honey)
| Feature |
Detail |
| Orifice |
8mm, 10mm, 12mm |
| Operation |
Snap open, snap closed |
| Special feature |
Self-cleaning nozzle - honey pulls back inside |
| Best for |
Runny to medium honey |
Screw Cap (Best for Thick Honey)
| Feature |
Detail |
| Orifice |
12mm, 15mm, 20mm |
| Operation |
Twist on, twist off |
| Special feature |
Induction liner for freshness |
| Best for |
Thick, crystallized honey |
Sports Cap (Best for On-the-Go)
| Feature |
Detail |
| Orifice |
6mm, 8mm |
| Operation |
Push to open, pull to close |
| Special feature |
Zero leaks in bags |
| Best for |
Travel, lunch boxes |
Custom Printing for Portion Packs & Spout Pouches
Printing Methods
| Method |
Best For |
Colors |
Quality |
| Rotogravure |
High volume (1M+ packs) |
Up to 10 |
Photorealistic |
| Flexography |
Medium volume (100k-1M) |
Up to 8 |
Very good |
What to Print on Portion Packs
| Information |
Why It Matters |
| Brand name |
Recognition |
| Product name |
"Ketchup," "Honey," "Mustard" |
| Tear here arrow |
Shows where to open |
| Expiration date |
Food safety |
| Barcode |
Scanning at checkout |
| Nutritional info |
Legal requirement (some markets) |
What to Print on Spout Pouches
| Element |
Purpose |
| Full-brand graphics |
Shelf impact |
| Product photography |
Appetite appeal |
| Usage instructions |
"Squeeze to dispense" |
| Recipes or QR code |
Engagement |
| Net weight |
Legal requirement |
| Certifications |
"Organic," "Pure," "Raw" |
Design Tips
- For ketchup: Use red. Show fries or burgers
- For honey: Use warm gold and amber. Show a drizzle shot
- For juice: Use bright fruit colors. Show the fruit
- Keep text readable - minimum 6pt font
- Leave room for tear notch - don't print important text where the notch will be
Quality Assurance
Testing for Portion Packs
| Test |
What It Checks |
Standard |
| Seal strength |
Will the seals hold? |
>20 N/15mm |
| Burst test |
Under pressure? |
No failure at 25 PSI |
| Leak test |
Truly sealed? |
Zero leaks under vacuum |
| Tear notch test |
Easy to open? |
Consistent tear path |
Testing for Spout Pouches
| Test |
What It Checks |
Standard |
| Seal strength |
Pouch seals |
>25 N/15mm (3-layer), >35 N/15mm (4-layer) |
| Spout pull force |
Spout stays attached |
>80 N |
| Leak test |
Spout-pouch junction |
Zero leaks at 25 in Hg |
| Drop test |
Survives falls |
1.5m, no separation |
Certifications
| Certification |
Portion Packs |
Spout Pouches |
| ISO 9001:2015 |
✓ |
✓ |
| FDA food contact |
✓ |
✓ |
| EU 10/2011 |
✓ |
✓ |
| BPA-free |
✓ |
✓ |
| Halal/Kosher |
Available |
Available |
Applications
Portion Pack Applications (5-30ml)
| Product |
Typical Size |
Film Recommendation |
| Ketchup |
9-10ml |
2-layer PET/PE |
| Mustard |
8-10ml |
2-layer or 3-layer |
| Mayonnaise |
10-15ml |
3-layer (oil resistance) |
| Soy sauce |
5-10ml |
2-layer |
| Honey |
10-20ml |
3-layer (moisture barrier) |
| Salad dressing |
15-30ml |
3-layer (oil resistance) |
| Hot sauce |
5-10ml |
2-layer (acid resistance) |
Spout Pouch Applications (50-1000ml)
| Product |
Popular Size |
Film Recommendation |
| Honey |
250ml, 500ml |
3-layer or 4-layer |
| Maple syrup |
250ml, 500ml |
3-layer (hot-fill) |
| Fruit puree |
100ml, 200ml |
4-layer (with PA) |
| Juice concentrate |
200ml, 500ml |
3-layer |
| Liquid supplements |
150ml, 300ml |
4-layer (with AL) |
| Baby food puree |
100ml, 150ml |
4-layer (sterilization) |
Production and Ordering
Lead Times for Portion Packs
| Phase |
Time |
| Cylinder/plate making |
7-15 days |
| Material procurement |
5-10 days |
| Printing |
3-5 days |
| Pouch forming |
5-10 days |
| Quality inspection |
2-3 days |
| Packaging |
2-3 days |
Total: 20-35 working days
Lead Times for Spout Pouches
| Phase |
Time |
| Cylinder/plate making |
7-20 days |
| Material procurement |
5-10 days |
| Lamination |
3-5 days |
| Printing |
3-7 days |
| Pouch forming + spout |
5-10 days |
| Quality inspection |
2-3 days |
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