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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)
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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Company Details
Bronze Gleitlager
,
Bronze Sleeve Bushings
and
Graphite Plugged Bushings
from Quality China Factory
Business Type:
Manufacturer
Total Annual:
3000000-5000000
Employee Number:
80~100
Ecer Certification:
Verified Supplier
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