{"id":532,"date":"2026-10-09T14:43:37","date_gmt":"2026-10-09T06:43:37","guid":{"rendered":"http:\/\/www.novdim.com\/blog\/?p=532"},"modified":"2026-10-09T14:43:37","modified_gmt":"2026-10-09T06:43:37","slug":"how-to-choose-the-right-size-of-sachet-for-tea-packing-4640-9ee1e5","status":"publish","type":"post","link":"http:\/\/www.novdim.com\/blog\/2026\/10\/09\/how-to-choose-the-right-size-of-sachet-for-tea-packing-4640-9ee1e5\/","title":{"rendered":"How to choose the right size of sachet for tea packing?"},"content":{"rendered":"

Hey there! If you\u2019re a tea brand owner, small-batch roaster, or even a caf\u00e9 guy who\u2019s ever stared at a roll of empty tea sachets thinking \u201cwait, will this fit my blend?\u201d, I feel you. I\u2019ve spent the last 8 years on the ground at our tea sachet packing shop, fielding calls at 9 AM from panicking clients who just ordered the wrong size and now have 500 sachets that are either crammed too tight or way too big (looking at you, the client who bought 10x12cm sachets for 2g of white tea\u2014we still laugh about that). Choosing the right sachet size isn\u2019t just \u201chow much tea do I want in there?\u201d It\u2019s part science, part knowing how your customers are actually going to use it, and part not wasting your cash on extra material. Let\u2019s break this down like we\u2019re chatting over a coffee (or a pot of your favorite tea, duh). Sachet for Tea Packing<\/a><\/p>\n

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First off, let\u2019s get one thing straight: there\u2019s no universal \u201cperfect\u201d size. I see it all the time\u2014new clients come in asking for the \u201cstandard sachet\u201d and then they\u2019re surprised when it doesn\u2019t work for their smoky Lapsang Souchong that puffs up like a balloon when steeped. So let\u2019s start with the basics that actually matter, not the random sizes the big box stores push.<\/p>\n

First, let\u2019s talk about tea volume, but not just the dry weight. Wait, why? Because loose tea leaves aren\u2019t little pellets that stay the same shape\u2014they expand. Like, if you\u2019ve ever put a handful of green tea in a mug and watched it unfurl, you know exactly what I mean. So if you just go by weight, you\u2019re gonna have a bad time. Let\u2019s take an example: 2 grams of regular black tea (nothing too chunky) is about 5-6 cm\u00b3 when dry, but once it\u2019s steeped, it doubles in volume. Chunky stuff, like whole-leaf oolong or herbal blends with big dried mint, is way more\u20142 grams of chunky oolong could be 8-10 cm\u00b3 dry, and expand to 15 cm\u00b3 when wet. So if you pick a sachet that\u2019s only 6x8cm, that 2g oolong\u2019s gonna burst through the seams when it hits hot water. I\u2019ve seen it happen\u2014client\u2019s sachets split mid-brew, left customers with a mug full of tea leaves, and a one-star review on Amazon. Not the vibe.<\/p>\n

Next up: how is your tea being packed? Are you doing single-serve sachets for takeaway? Individual sachets for retail boxes? Or bulk sachets for cafes that steep multiple cups at once? Each use case needs a totally different size. Let\u2019s take single-serve retail sachets first, because that\u2019s what 90% of our small business clients come to us for. For your average everyday tea\u2014black, green, white, the kind you drink from a standard 8oz mug\u2014you\u2019re looking at a sachet that\u2019s roughly 7x10cm (that\u2019s width x length, fyi\u2014we always write size as WxL, not the other way around, because width is how it fits in your mug). Wait, but let\u2019s adjust for weight here: if you\u2019re packing 2.5g of fine green tea (the kind that\u2019s super powdery, barely expands), 6x8cm works. If you\u2019re packing 3.5g of whole-leaf black tea that puffs a bit, 7x10cm is safer. I had a client a month ago who insisted he could use 6x9cm for 3.5g of chunky oolong, and when he tested a prototype, half the sachets burst. We swapped to 7x11cm, and now his reviews say the sachets \u201chold their shape while brewing\u201d \u2014 exactly what you want.<\/p>\n

Then there\u2019s those of you doing caf\u00e9 or bulk sachets. If a caf\u00e9 is using a 12oz pot and wants to steep 5g of tea, you\u2019re not doing a single 7x10cm sachet\u2014you need something bigger, like 8x12cm or even 9x13cm. Wait, but why so big? Because when 5g of whole-leaf black or herbal tea expands, it\u2019s going to take up a lot of space in a pot. If you cram it into a small sachet, the tea can\u2019t circulate properly, so the brew is weak. I learned that the hard way early on\u2014our first big caf\u00e9 client ordered tiny sachets, and they complained their brews were too light. We adjusted the size, and their sales went up 18% in two months because customers actually liked how strong their tea was. It\u2019s not magic\u2014it\u2019s space.<\/p>\n

Now, let\u2019s talk about small details that most people skip, but make all the difference. First, mesh size? Wait no, size first, but the size ties into mesh. No, wait\u2014seam allowance! Oh my god, that\u2019s a big one I see new clients miss. When you buy a sachet blank, you have to account for the sealed edges. Most sachet blanks have a 0.5cm seam on all sides, so if you pick a sachet that\u2019s 7x10cm before<\/em> sealing, the actual inside space is 6x9cm. That\u2019s a huge difference! So if you\u2019re calculating, don\u2019t use the full listed size\u2014subtract 1cm total from each dimension for seams. I once had a client order 6x8cm sachets, and when we sealed them, the inside was 5x7cm. He was trying to fit 3g of tea in there, which is impossible, because even 3g of fine tea is 5cm\u00b3. He ended up having to reorder everything, which cost him time and cash. Always, always ask for the internal volume, not the external listed size. We tell all our clients that up front, but I still see this mistake all the time.<\/p>\n

Another detail: customer behavior. How is your customer using the sachet? Are they tossing it into a mug and leaving it there while they work? Are they using a tea infuser that\u2019s slightly smaller than a mug? Are they even pulling the sachet out after 3 minutes, or leaving it to steep for 10? If someone leaves the sachet in while they drink, it\u2019s going to expand more than if they pull it out. So if your customers are the \u201clet it steep all morning\u201d type, go up a size. I have a client who sells tea for office break rooms, and their customers leave the sachets in the pot for 15 minutes. We size their sachets 1cm bigger than we\u2019d do for retail, and they haven\u2019t had a burst sachet complaint in 3 years.<\/p>\n

What about specialty teas? Chunky whole-leaf oolongs, herbal blends with big dried rose hips or chamomile, matcha that\u2019s super fine? Those need special sizing. For whole-leaf oolong, which is big and bulky, you need at least 8x12cm for 5g, because those leaves can expand to almost double their dry size. Matcha, on the other hand, is super fine, so you can get away with smaller sachets\u20146x9cm for 1.5g is totally fine, because it doesn\u2019t expand much, and you don\u2019t want a tiny tea bag floating around in your mug looking sad. I recently worked with a matcha brand that was using 7x10cm sachets, and they said the matcha was \u201cclumping at the bottom because there was too much extra space\u201d. Swapped to 6x9cm, and they got way less clumping. That\u2019s the kind of small tweak that makes a big difference for your brand\u2019s reviews.<\/p>\n

Wait, also: packaging aesthetics. If you\u2019re putting the sachet in a retail box that\u2019s 5cm wide, a sachet that\u2019s 7cm wide is gonna stick out, look messy, and waste space in your packaging. So don\u2019t just think about how it fits in the mug\u2014think about how it looks on the shelf. I had a client who made beautiful tin boxes that were exactly 7cm wide, so we sized his sachet to 6.5cm wide, so it fit perfectly, looked neat in the tin, and the customer could see the tea through the sachet mesh. It\u2019s a tiny thing, but customers notice when a product looks polished, not like it was crammed together last minute.<\/p>\n

Let\u2019s run through a quick cheat sheet, because I know you\u2019re skimming (no judgment, I do it too when I\u2019m researching stuff). Here\u2019s what we recommend for common tea types and uses:<\/p>\n