Custom Printed Salt Packaging.

Salt needs a moisture barrier, because plain paper lets water vapour straight through. Salt draws water from the air and sets into a lump that will not pour, so the barrier works against moisture coming in rather than anything getting out. The classic structure is paper for the print, foil for the barrier and PE to seal.

Uncoated paper is the one thing we will not run for this product, since the sachet stops doing its job in the first humid week.

Salt is corrosive to some materials, so the inner layer that touches it has to be one it does not attack. A PE sealant layer is inert against salt and is what makes the seal, with the foil sitting behind it out of contact. Getting the liner wrong shows up as pinholes and a pack that stops being a barrier.

The pack is also heavy for its size. Base seals and side seams carry real load, so the seal width is set for weight rather than the minimum the film allows.

An easy-tear sealant layer lets the sachet open cleanly across the top from a notch. Standard sealant films stretch and resist, which is how a diner ends up with salt across the table. The easy-tear grade fractures in a straight line, and the printed tear-notch marking shows where to start.

Resealing is not part of this format. Portion sachets are single-use, and a reclosable salt pack is a different structure.

Flexo in one or two colours is the standard, with full CMYK where the sachet is a branded piece. High-volume condiment sachets carry a logo and the mandatory text and nothing more. Speciality and sea salt brands go for a kraft outer with a natural look, or a metallic reveal that leaves areas unprinted so the foil shows through.

Unprinted stock is available for bulk and white-label supply.

Sachets are sized by fill weight in grams, and the outside dimensions follow from that. A portion-control sachet is specified to the gram, and the sachet dimensions come from the fill and the sealing machine. Typical flat pouches run around 4 by 6 inches and cartons around 3 by 2 by 5 inches.

Roll stock for a form-fill-seal line is supplied on a reel cut to your machine's web width and repeat length.

Pre-made sachets and pouches are quoted from 500 units. Salt is a high-volume product and the economics improve sharply past 1,000, which is where the tiered pricing begins. A production order can run to 100,000 sachets.

Roll stock for a form-fill-seal line is quoted by reel length instead, and the equivalent minimum works out similar.

Production takes 7 to 10 business days once the artwork is approved. Rush production is 5 to 7 business days for a launch that cannot wait. Printed samples of the laminate take 5 to 7 business days, and if you go ahead with the bulk order the sample fee is credited against it.

Roll stock needs the machine specification up front, so send web width and repeat with the artwork.

Foil laminate is the full barrier, and metallised film costs less and is enough for normal storage. A true aluminium foil layer stops moisture completely, which suits a sachet that may sit in a warm kitchen for months. Metallised film carries a thin deposited metal layer and holds well in a dry store with steady turnover.

Neither is plain paper, and neither can be recycled as paper. The paper outer gives print quality and feel, and the metal layer gives the barrier.