Custom Energy Gel Packets
An energy gel is opened at pace, with one hand, often with the pack held in the teeth. Every packaging decision follows from that moment, and almost none of it is about the printed panel.
Skip the blank page
You already know what you are packaging, so there is nothing to set up. This opens the design engine with the flat pouch / 3-side seal structures on screen — then you type your own dimensions and the dieline is generated at that exact size.
The structures energy gel packets actually ship in
Every one of these is a construction TWOFORM generates a real production dieline for, at your own dimensions — not a template you have to fit your product into. Each opens the engine already on that package type.
Settle this before you design
The torn-off top has to stay attached or it becomes litter
A tear-off strip dropped on a course is the fastest way for a brand to be banned from an event. The fix is structural: a notch that leaves the strip attached, or a wide enough tear that the whole top folds back rather than separating. Decide this before the artwork, because it changes where the notch and the seal band sit.
The mistake that costs a print run
Sticky product on the seal band
Gels are filled hot or thin and set thicker, and any product that touches the seal band during filling makes a weak seal that survives the warehouse and fails in a jersey pocket. That is a filling issue, but the packaging decision that helps is a taller seal band — so leave it clear in the artwork rather than pushing the design into it.
How you actually make it
- Open the structure above and type your real dimensions. The dieline is generated at that exact size and validated against real manufacturing limits as it draws — if a size cannot be folded, glued and shipped, it says so before you design anything on it.
- Describe your brand and the AI designs the artwork directly onto that dieline — not onto a picture of a package.
- Place your own logo, barcode and any required panel yourself. The AI leaves them exactly as placed unless you ask it to change them.
- Fold it in live 3D to check it, then download print-ready files to use with any printer — or have TWOFORM manufacture it.
Questions about custom energy gel packets
What size sachet holds a 40 g gel?
Around 3 × 5.5in as a flat three-side-seal pouch. The pack is deliberately narrow so it can be held and squeezed one-handed rather than sized purely by volume.
Flat sachet or stick for a gel?
Flat if it is taken all at once and the pack is discarded; stick if the athlete takes part of it, resealing is not expected, and carrying it in a belt matters more than the printed panel.
How do I stop the tear-off strip becoming litter?
Design it not to detach. A notch that leaves the strip hinged, or a wider tear that folds the top back, solves it structurally — nothing printed on the pack will.