Custom Sauce Pouches
Pouching a sauce swaps glass for film and immediately raises three questions the bottle never asked: where the spout goes, how hot the product is when it goes in, and how the pack behaves lying on its side.
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 spout pouch structures on screen — then you type your own dimensions and the dieline is generated at that exact size.
The structures sauce pouches 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 spout position is fixed before anything is designed
A fitment is welded into the top seal — either centred or in one corner — and the weld destroys the artwork underneath it. Corner spouts pour better and centre spouts stand better. Choose which, mark the patch as unprintable, and design the panel around it rather than discovering the conflict after the artwork is approved.
The mistake that costs a print run
Forgetting that a filled pouch is not the shape you drew
A litre of sauce makes the pouch bulge into a rounded cushion. Type that runs to the edges of the flat artboard curves out of sight, and a full-bleed photograph distorts across the belly. Keep critical copy in a narrower central column than feels necessary, and check the design against the filled shape, not the flat one.
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 sauce pouches
Can hot-filled sauce go into a pouch?
It can, but the film structure has to be specified for the fill temperature and the pouch will distort as it cools if the headspace is wrong. Settle the fill temperature with your co-packer before choosing the laminate.
Corner spout or top-centre spout?
Corner if the product will be poured — it gives a controlled stream and drains the pouch. Centre if the pouch has to stand on a shelf with the cap upright and look symmetrical.
How much sauce fits in a stand-up pouch?
A 7 × 10in pouch with a 3.5in gusset holds roughly a pint with sensible headspace. Liquids fill a pouch far more completely than powders, so the usable volume is close to the geometric volume.