Single-Serve Powder Sachet Sizing and Dieline Project

Project brief

A nutrition brand needed slim center-seal sachets for single-serve powder products with different serving sizes. The main powder portion required enough volume and headspace without making the pack feel oversized.

Project challenge

The original proposed dimensions felt too tight once the actual serving was considered. Because powder density varies, choosing a size from fill weight alone would have created avoidable risk.

Packaging approach

• Paper pouch mockups used to test actual powder fit
• Dimensions revised after hands-on fill checks
• Separate center-seal dielines prepared for different serving formats
• Artwork supplied against the confirmed dielines
• Files reviewed before deposit and production planning

Validation points

The sizing process considered powder density, target serving, headspace, pack proportions, artwork area, and seal zones. The team avoided presenting one standard sachet size as suitable for every powder.

Outcome

The customer validated the revised format through physical paper tests, the dielines were updated, artwork was reviewed, and the project advanced into production preparation. This is a practical example of using low-cost fit checks before committing to printed packaging.