Tear-Notch Flat Pouches for Carbohydrate Energy Gels
Single-serve carbohydrate energy gels demand packaging that is compact enough for jersey pockets yet strong enough to survive repeated squeezing without micro-leaks. Our 3-side seal flat pouches are engineered with puncture-resistant, high-barrier films that protect viscous gel formulas from oxygen ingress and moisture loss during transport, race-day storage, and on-the-go consumption.
The tear-notch opening delivers fast, one-handed access during running or cycling, while the slim flat profile maximizes branding space per gram of product. The water-resistant soft-matte exterior supports bold full-color digital printing — ideal for flavor callouts, caffeine content, electrolyte panels, and race-day sampling programs that need to look sharp under retail and event lighting.
Key Points
- Compact 3-side seal flat format for pocket carry
- Tear-notch for fast one-handed gel access
- High-barrier film protects viscous carbohydrate formulas
- Puncture-resistant structure for daily athletic use
- Ideal for GU-style single-serve energy gels
- Custom printing available from 200 pcs
Typical Structure
- PET / PE (standard)
- PET / VMPET / PE (enhanced barrier)
- PET / AL / PE (high barrier for electrolyte and functional gels)
Sizes We Commonly Produce
- 30g / 32g (1 oz)
- 40g / 60ml (2 fl oz)
- 90g / 100ml
- Custom sizes available based on your fill volume
Closure Options
- Tear notch
- Corner or center spout with screw cap
- Resealable zipper (multi-pack formats)
Lead Time
- Production: 10–15 days
- Delivery: 7–14 working days (DDP available)