How I Launched My Tea Brand Without Cylinder Costs Using Printed Pouches

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.

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