Launching a tea or masala brand sounds exciting—until you face the first big hurdle: packaging.Like many first-time entrepreneurs, I found myself stuck at the cylinder cost stage. To print each design on a pouch—whether it’s 50g, 100g, 250g, 500g or 1kg—you need to create a separate set of cylinders for each SKU. The cost? Easily ₹15,000–₹50,000 per design per size. Add the high minimum order quantities (MOQs) and you’re looking at lakh-level investments before even selling your first pouch.But there’s good news. I discovered a smarter, scalable, and budget-friendly way to start small and grow: ready-made printed pouches and digital pouch printing without cylinders.
The Problem: Cylinder-Based Printing Costs Are a Trap
Here’s what most new founders don’t realize until it’s too late:
- Cylinder printing (also called rotogravure printing) demands separate engraved cylinders for each color and size.
- Even if you want just 500 pieces per SKU, the setup cost is the same as for 50,000.
- You also need to finalize your designs upfront—leaving little room for testing, experimenting, or rebranding.
For a startup, this is a cash flow killer.
The Solution: Launch Smart with Printed Pouches Without Cylinder Investment
Instead of going the traditional route, I turned to readymade packaging pouches from brands like Swisspac and Pouch Makers.
These companies offer two brilliant options:
- Ready-stock plain or colored pouches – just apply your custom sticker labels and start selling.
- Digitally printed pouches – your brand is printed without cylinders, with low MOQ starting from 500-1000 pieces.
This allowed me to:
- Launch multiple SKUs with low risk
- Test my market before investing in bulk
- Use high-quality food-grade, laminated barrier pouches
- Reorder only what sells
Types of Pouches Available (No Cylinder Needed)
Whether you’re packaging masalas, loose leaf tea, herbal powders, or even superfoods, these pouch types are readily available:
| Pouch Type | Best For | Available Without Cylinder? |
|---|---|---|
| Stand-up Pouches (SUPs) | Tea, masala, powders | ✅ Yes |
| Zip-lock or Resealable | Reusable masala or spice packs | ✅ Yes |
| Kraft Paper Pouches | Organic or artisanal branding | ✅ Yes |
| Spout Pouches | Liquid masala pastes, chutneys | ✅ Yes |
| Pillow Pouches | Cost-effective packaging | ✅ Yes |
| Flat Bottom/Gusseted | High-volume masala/tea | ✅ Yes |
| Window Pouches | Showcasing product visibility | ✅ Yes |
| Retort Pouches | Heat-treated or long-shelf life SKUs | ✅ Yes |
🏭 Top Suppliers of Printed Stand-Up Pouches Without Cylinders
Here are some reliable packaging suppliers offering digital printing & stock pouches without cylinder cost:
| Supplier | Location | Website | Features |
|---|---|---|---|
| Swisspac India | Gujarat | swisspac.in | Digital + stock pouches, eco |
| Pouch Makers | Mumbai | pouchmakers.in | No cylinder MOQ, premium finish |
| Packman Packaging | Delhi NCR | packman.in | Stand-up, kraft, spout, retort |
| Omprakash Packaging | Gujarat | omprakashpackaging.com | Zipper, paper, digital pouches |
| Uflex Limited | Global | uflexltd.com | Large scale flexible packaging |
| NorthPack India | Pan India | northpackindia.com | Product consultancy + packaging |
You can also explore platforms like IndiaMART, TradeIndia, and Alibaba for local or international suppliers.
Pro Tips for Starting Your Brand Cost-Efficiently
- Start with blank stock pouches and high-quality stickers to brand your packaging.
- Use digitally printed pouches as you grow — no cylinder, no commitment, high quality.
- Invest in a manual or semi-automatic sealing machine for airtight packaging.
- Opt for zip-lock pouches for consumer convenience and freshness.
- Stick to universal sizes initially (like 100g or 250g) to reduce SKU complexity.
- Choose metalized or aluminum-laminated barrier layers for better shelf life of masalas and teas.
Why Digitally Printed Pouches Are the Future for Startups
- No cylinder cost — save ₹40,000+ instantly
- Short-run friendly — order 500, not 50,000
- Fast turnaround time — launch new flavors quickly
- Eco-friendly options — recyclable, compostable, mono-materials
- Custom printing — add QR codes, seasonal offers, or traceability
My Own Experience
When I started, I avoided the trap of large MOQ rotogravure printing and instead bought 1000 printed stand-up pouches from Swisspac and another batch of plain kraft pouches to which I added custom labels printed locally.
It gave me:
- Low inventory risk
- Room to tweak design
- Money saved to invest in marketing instead
Now as my sales are growing, I’ve moved into custom digitally printed pouches in larger runs—still without investing in cylinders.
Final Thoughts
If you’re launching a tea, spice, or masala brand, don’t let packaging costs hold you back. Use digitally printed pouches, printed stand-up pouches, or stock pouches with labels to launch lean and scale smart.
By skipping the need for expensive cylinders, you save money, stay flexible, and bring your product to market faster.
