Irregular Shape Sachet Machine | Jelly Packaging Machine & Shaped Pouch Liquid Filler
BY-JLS160Y · BY-JLC160Y · BY-JLS180G · Shaped Pouch Liquid Packing Machine · Jelly Packaging Machine
Every sachet on your competitor’s shelf looks the same. Rectangular. Pillow-sealed. Forgettable.
A custom shape sachet changes that in the most immediate way possible: the moment a consumer sees it. A jelly pouch shaped like a fruit. A cosmetic serum sachet with a tapered neck. A ketchup portion that fits the curve of a plate. These are not packaging gimmicks — they are brand signals that communicate premium quality, category leadership, and product confidence before the consumer reads a single word of copy.
The BY-JLS160Y, BY-JLC160Y, and BY-JLS180G are dedicated irregular shape sachet machines built for liquid and paste products that deserve more than a standard rectangular pouch. Four-side seal, side seal, and three-side seal configurations — for jelly, honey, sauces, cosmetic samples, and functional drinks — with custom die-cut shape tooling that makes your pouch format a proprietary brand asset.
KPI bar:
- 3 seal formats — 4-side · side seal · 3-side seal
- 1–50 g Measuring range across models
- 10–50 bag/min Production speed
- Unlimited Custom shape possibilities
CTA buttons:
- [Request a Free Shape Sample Trial →]
- [Download Shaped Pouch Catalog]
The Packaging Decision That Most Manufacturers Leave on the Table
Why Shape Is Your Most Underused Brand Weapon
Walk into any supermarket category — jelly snacks, condiment sachets, single-serve cosmetics, sports nutrition gels — and count how many brands are using standard rectangular pouches versus custom-shaped packaging. In most categories, the ratio is 90% standard to 10% shaped. The 10% are almost always the premium-positioned brands, the category leaders, or the brands that are growing fastest.
This is not a coincidence. It reflects a basic truth about how consumers process visual information at retail: shape registers before colour, before text, and before any conscious evaluation. A jelly sachet shaped like a strawberry communicates flavour, freshness, and quality in a fraction of a second. A cosmetic sample sachet with a premium silhouette signals luxury before the consumer reads the brand name. A ketchup portion that sits flat and presents well on a restaurant table communicates attention to detail that a generic pillow sachet cannot.
For most manufacturers, the reason they are not using custom-shaped sachets is not preference — it is the assumption that shaped pouch production requires specialised, expensive, single-purpose equipment that is only accessible to large-scale operations. This assumption is no longer accurate. The BY-JLS and BY-JLC machine series brings custom shape sachet production within reach of mid-scale manufacturers across food, pharmaceutical, and cosmetic applications.
What Makes These Shaped Pouch Machines Work
All three models in the BY-JLS / BY-JLC series share the same core technology platform — the same PLC control system, the same filling mechanism approach, and the same equipment characteristic principles. The seal format and shape tooling are what differentiate them. Understanding the shared technology helps you evaluate the platform as a whole rather than each model in isolation.
Custom Shape Die Tooling — Your Brand’s Proprietary Asset
The shape of your pouch is defined by the die-cut tooling fitted to the machine. Unlike standard rectangular sachets, where the pouch shape is simply the natural output of the film forming tube, custom shape sachets require a precision die that cuts the film to your specific profile before or during sealing. This tooling is designed and manufactured to your brief — and once it exists, it belongs to your production line. A competitor cannot replicate your pouch shape without their own tooling investment.
The die tooling lead time and cost should be factored into your project timeline. For new entrants to shaped sachet packaging, we recommend finalising your pouch shape concept with your marketing team before engaging on machine specification — because the shape brief drives the tooling design, which in turn drives specific machine configuration requirements.
PLC Intelligent Automation
Advanced PLC control with real-time sensor feedback automates the full production sequence across all three models: product feeding, film forming, filling, sealing, die-cutting, and date coding — in one continuous flow. Parameters including fill volume, seal temperature, seal dwell time, bag dimensions, and production speed are stored in product profiles on the touchscreen. Changeover between product SKUs is a profile recall, not a rebuild.
The PLC also monitors seal jaw temperature in real time, alerting operators to deviations before they generate defective product — a critical feature for shaped pouch production, where a seal failure in a custom-shaped pouch is more visually obvious and more commercially damaging than in a standard rectangular sachet.
Versatile Material Compatibility
All three models handle the same broad product range: free-flowing liquids (juices, water, soy sauce), medium-viscosity products (ketchup, salad dressing, jam), and high-viscosity pastes and gels (honey, cosmetic cream, pharmaceutical gel, jelly). For high-viscosity products, the temperature-controlled product pathway option maintains consistent fill temperature and viscosity through the production shift — the same mechanism that makes the BY-JLB160Y effective for honey applies here.
Customisable Add-Ons
All models support: easy-tear notch, exhaust valve, perforation, and custom shape punch dies. For children’s jelly products, the easy-tear notch is standard practice — small children cannot reliably open a sachet that requires scissors. For premium adult health gel products, the tear notch can be integrated into the shaped profile itself as a design element rather than an afterthought.
From Jelly Snacks to Cosmetic Serums — The Full Application Range
Food & Snack Jelly (果冻) — the primary application for BY-JLS180G · Jam portions · Fruit puree · Honey (蜂蜜) · Plant-based juice concentrate · Ketchup (番茄酱) · Shaped sauce sachets · Salad dressing · Oyster sauce · Chilli paste
→ Jelly Packaging Machine: The BY-JLS180G is the category-standard machine for retail jelly snacks in fruit and animal shapes. The three-side seal format produces the stand-up pouch silhouette that defines the category. Custom die tooling creates the fruit, animal, or character shapes that make children’s jelly products recognisable on shelf from across the aisle.
Cosmetic & Personal Care Facial serum sample sachet · Essence liquid sachet · Toner sachet · Sheet mask liquid · Shampoo trial sachet · Cosmetic cream sample · Lotion portion
→ Shaped Pouch for Cosmetics: The four-side seal BY-JLS160Y and side-seal BY-JLC160Y are the preferred formats for premium cosmetic sample sachets. A shaped cosmetic sachet — tapered, curved, or silhouette-branded — communicates product quality at the sample stage and drives trial-to-purchase conversion more effectively than a generic rectangle.
Pharmaceutical & Health Oral liquid medicine · Chinese medicine soup liquid concentrate · Probiotic oral liquid · Functional drink gel · Sports nutrition gel · Electrolyte gel · Nutritional paste for paediatric applications
Daily Chemical Disinfectant liquid portions · Hand sanitiser sachet · Industrial lotion single-serve · Pesticide liquid portions
Which Model Is Right for Your Product and Shape?
Choosing between the three models depends on three questions: what shape profile you want, what seal format best suits your product’s fill weight and viscosity, and what end-use the sachet is designed for. This guide narrows the choice.
Choose BY-JLS160Y (4-side seal) if: Your product is a liquid or paste at fill weights of 1–50 g and you want maximum pouch flatness and structural rigidity. Your application is cosmetic samples, premium sauce portions, or pharmaceutical gel where lay-flat presentation matters. Your shape concept is wide-format — a shape that is as wide as it is tall, or wider.
Choose BY-JLC160Y (side seal) if: Your product is a liquid at fill weights of 1–40 g (do not exceed 50 g) and your shape concept is tall and narrow — a slender cosmetic essence sachet, an elongated jelly tube, an upright single-serve drink portion. Your consumer will tear the top and consume directly from the opening. Your brand positioning is premium and the vertical silhouette is central to the visual identity.
Choose BY-JLS180G (3-side seal) if: Your product is jelly, jam, fruit puree, or a paste product at 5–30 g (standard) or 5–50 g (extended). Your shape concept is the classic jelly pouch — a stand-up shaped body with a sealed top. Your target consumer is children (fruit shapes, animal shapes, character shapes) or health-conscious adults (rounded premium forms for nutritional gel or probiotic paste). This is the machine for the jelly packaging machine application specifically.
Не уверен? Describe your product, your target fill weight, and your shape concept to our engineers. We will recommend the right model and arrange a shape trial with your actual product and a sample die before you commit.
Why the Investment in Shaped Pouch Tooling Pays Back
Custom shape sachet production requires one additional investment that standard sachet packaging does not: the die tooling that creates your pouch shape. This is a fixed, one-time cost per shape design. Once it exists, your per-sachet production cost is essentially the same as for a standard rectangular sachet — the machine runs at the same speed, uses the same film, and requires the same labour.
The business case for absorbing the tooling cost rests on three value drivers that most manufacturers underestimate until they have made the transition.
Shelf differentiation at zero ongoing premium. A custom-shaped jelly sachet on a retail shelf next to standard rectangular competitors catches the eye first. In a category where the consumer is choosing quickly and the primary driver is visual appeal — children’s snacks, impulse confectionery, single-serve condiments — being the visually distinctive option is a significant commercial advantage. The tooling investment is amortised over every sachet produced; after the first production run, the differentiation is essentially free.
Retailer listing advantage. Retailers managing category space consistently prefer to list products that create visual variety within a section. A shaped sachet in a category of rectangles justifies shelf space in a way that another rectangular sachet in a slightly different colour does not. For brands trying to access new retail listings or expand from local to export markets, the shaped pouch is a genuine negotiating asset.
Sample-to-purchase conversion for cosmetics. In the cosmetic and personal care category, a shaped sachet sample communicates brand premium at the trial stage and drives higher conversion to full-size purchase than a generic sample sachet. The investment in shaped tooling for cosmetic samples is among the fastest-payback packaging decisions in that category.
From Jelly Snacks to Cosmetic Serums — The Full Application Range
Food & Snack Jelly (果冻) — the primary application for BY-JLS180G · Jam portions · Fruit puree · Honey (蜂蜜) · Plant-based juice concentrate · Ketchup (番茄酱) · Shaped sauce sachets · Salad dressing · Oyster sauce · Chilli paste
→ Jelly Packaging Machine: The BY-JLS180G is the category-standard machine for retail jelly snacks in fruit and animal shapes. The three-side seal format produces the stand-up pouch silhouette that defines the category. Custom die tooling creates the fruit, animal, or character shapes that make children’s jelly products recognisable on shelf from across the aisle.
Cosmetic & Personal Care Facial serum sample sachet · Essence liquid sachet · Toner sachet · Sheet mask liquid · Shampoo trial sachet · Cosmetic cream sample · Lotion portion
→ Shaped Pouch for Cosmetics: The four-side seal BY-JLS160Y and side-seal BY-JLC160Y are the preferred formats for premium cosmetic sample sachets. A shaped cosmetic sachet — tapered, curved, or silhouette-branded — communicates product quality at the sample stage and drives trial-to-purchase conversion more effectively than a generic rectangle.
Pharmaceutical & Health Oral liquid medicine · Chinese medicine soup liquid concentrate · Probiotic oral liquid · Functional drink gel · Sports nutrition gel · Electrolyte gel · Nutritional paste for paediatric applications
Daily Chemical Disinfectant liquid portions · Hand sanitiser sachet · Industrial lotion single-serve · Pesticide liquid portions
Why Manufacturers Choose Fill-Package for Shaped Sachet Production
- Shape concept to sample pouches — send your concept, receive shaped trial pouches with fill data within 5 business days
- In-house die tooling expertise — custom shape dies designed and manufactured to your brief
- 24-hour engineer response — all technical and shape-design enquiries answered within one business day
- 95% repeat customer rate — shaped pouch clients return because the shapes, seals, and speeds deliver as specified
- Remote commissioning support — shape parameter setup and seal optimisation guidance via video call, globally available
- Spare parts in 48 hours — die components, sealing elements, and sensor spares held in stock
- On-site commissioning included — shape trial and operator training at your facility for orders within standard service regions
Choose Your Seal Format: The Foundation of Your Shaped Pouch Design
The seal format determines the shape possibilities, the structural integrity of the pouch under liquid pressure, and the visual character of the finished sachet. The three models in this series cover the three most commercially important seal formats for irregular shape liquid and paste packaging.
Three Machine Models, Three Seal Formats
The four-side seal format seals all four edges of the pouch, creating maximum structural rigidity and the cleanest, flattest pouch presentation. This is the preferred format for cosmetic sample sachets, premium condiment portions, and any application where the pouch needs to lie completely flat and present well on a retail surface or restaurant table. The four-seal structure also provides the highest seal-to-pouch-area ratio, which translates to the best leak resistance for liquid products under transport pressure.
Custom shape tooling for the BY-JLS160Y creates the pouch silhouette through the die-cut applied to all four sides — enabling truly bespoke shapes: tapered, curved, asymmetric, or brand-logo-inspired profiles. The pouch shape is your intellectual property and differentiates your product at the most fundamental packaging level.
| Спецификация | BY-JLS160Y |
|---|---|
| Seal type | 4-side seal (夹拉四边封) |
| Packing speed | 10–50 bag/min |
| Measuring range | 1–50 g |
| Bag size (L × W) | L: 50–180 mm · W: 50–280 mm |
| Источник питания | 220V / 50Hz / 2.0 KW |
| Machine weight | 320 KG |
| Dimensions (L×W×H) | 1250 × 900 × 1950 mm |
Лучше всего подходит для: Cosmetic serum samples · premium ketchup/sauce portions · honey sachets · pharmaceutical oral gel · functional drink concentrate
BY-JLC160Y — Side Seal Shaped Pouch Machine.
The side seal format creates a pouch sealed along both vertical sides and the bottom, with the top sealed after filling — producing a tall, narrow silhouette that stands upright. This is the preferred format for elongated shaped pouches: the slender cosmetic essence sachet, the tall fruit juice portion, the upright single-serve jelly. The side-seal structure naturally lends itself to elegant, vertical brand presentation and is particularly effective for products where the consumer tears the top and drinks or squeezes directly from the opening.
The BY-JLC160Y’s side-seal tooling enables curved side profiles, tapered waists, and shaped bottom forms — all of the visual complexity of premium standalone spouted pouches, at sachet scale and sachet economics.
Note: Side-seal sachets are not recommended for fill weights exceeding 50 g, as the side-seal geometry creates higher stress concentration at the seal corners under liquid pressure at larger fill volumes.
| Спецификация | BY-JLC160Y |
|---|---|
| Seal type | Side seal (夹拉侧边封) |
| Packing speed | 10–50 bag/min |
| Measuring range | 1–40 g |
| Bag size (L × W) | L: 50–180 mm · W: 50–280 mm |
| Источник питания | 220V / 50Hz / 2.0 KW |
| Machine weight | 320 KG |
| Dimensions (L×W×H) | 1250 × 900 × 1950 mm |
Лучше всего подходит для: Cosmetic liquid samples · tall jelly sachets · fruit juice portions · oral medicine liquid · premium beverage concentrate
The three-side seal format — sealed on the bottom and both sides, with the top formed during the bag-making process — is the classic jelly sachet configuration and the most versatile format for shaped pouch production across food and pharmaceutical paste applications. The BY-JLS180G produces the characteristic stand-up jelly pouch with a shaped body: fruit-profile shapes, animal shapes, character shapes for children’s products, and rounded premium forms for adult health products.
Two configuration options are available depending on fill weight requirements. The standard configuration handles 5–30 g, appropriate for retail jelly snacks, jam portions, and cosmetic paste samples. The extended configuration handles 5–50 g, appropriate for larger jelly portions, nutritional gel sachets, and paste pharmaceutical applications.
| Спецификация | BY-JLS180G (Standard) | BY-JLS180G (Extended) |
|---|---|---|
| Seal type | 3-side seal (夹拉三边封) | 3-side seal (夹拉三边封) |
| Packing speed | 10–50 bag/min | 10–50 bag/min |
| Measuring range | 5–30 g | 5–50 g |
| Bag size (L × W) | L: 50–180 mm · W: 50–280 mm | L: 50–180 mm · W: 50–280 mm |
| Источник питания | 220V / 50Hz / 2.0 KW | 220V / 50Hz / 2.0 KW |
| Machine weight | 320 KG | 320 KG |
| Dimensions (L×W×H) | 1250 × 900 × 1950 mm | 1250 × 900 × 1950 mm |
Лучше всего подходит для: Jelly snacks · fruit-flavoured gel · children’s nutrition pouches · jam portions · cosmetic paste samples · pharmaceutical paste
Сопутствующий продукт
Common Questions About Irregular Shape Sachet Machines
Die tooling is a one-time fixed cost per shape design — there is no minimum production volume requirement attached to the tooling itself. However, the economics of custom-shaped pouch production improve significantly at higher volumes, because the tooling cost is amortised across more units. We recommend discussing your projected annual volume when enquiring about tooling, so we can advise on the right tooling investment level for your business scale.
Lead time for custom die tooling depends on the complexity of the shape and our current production schedule. Simple shapes — rounded rectangles, basic fruit silhouettes — are typically faster than complex multi-curve or character shapes. Provide your shape concept (a sketch or CAD drawing is sufficient at the enquiry stage) and we will give you a specific lead time estimate. Factor the tooling lead time into your overall project timeline when planning a new product launch.
Yes. All three models can run standard rectangular sachet formats without the custom shape die fitted. This gives you flexibility to run shaped and standard formats on the same machine platform — useful for operations that want to offer both a standard-format product and a premium shaped variant in the same category.
The BY-JLS160Y uses a four-side seal — all four edges are sealed, producing a flat, wide-format pouch with maximum structural rigidity. The BY-JLC160Y uses a side seal — both vertical sides and the bottom are sealed, producing a tall, narrow pouch that stands upright. The choice between them depends on your shape concept and end-use: wide-format lay-flat applications use the 160Y; tall upright applications use the 160C. Maximum fill weight on the BY-JLC160Y is 40 g (not recommended above 50 g due to seal geometry stress at larger liquid fill volumes).
The BY-JLS180G handles any paste or gel product in the 5–50 g range (depending on configuration): jam, fruit puree, honey, cosmetic paste samples, pharmaceutical oral paste, nutritional gel, sports nutrition gel, and plant-based concentrate. The three-side seal format is the most versatile for stand-up shaped pouch applications across food, health, and cosmetic categories.
Yes — a product and shape trial is standard for all shaped sachet machine enquiries. Send your product sample, your target fill weight, and your shape concept. Our engineers will run a trial with a sample die, produce shaped pouches for your evaluation, and provide fill weight data and seal integrity assessment before you commit to any purchase.
Compatible films include: BOPP/PE, NY/PE, PET/AL/PE (aluminium foil laminate), transparent PE composites, and kraft paper composites for premium appearance. For food products (jelly, honey, jam), high-barrier NY/PE or PET/AL/PE is recommended. For cosmetic samples, transparent or translucent laminates that show the product are popular. For pharmaceutical applications, consult your film supplier for compliance requirements. We advise on film specification during the enquiry process.
Ready to Make Your Sachet the One They Remember?
Tell us your product, your target fill weight, and your shape idea — even a rough sketch is enough to start. Our engineers will match you to the right seal format and model, design a sample die, and produce shaped trial pouches with your actual product before you commit to any purchase decision.