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How to Make Sachets

Cut a 10 inch square piece of cotton with pinking shears to prevent raveling. I even pink the selvage to keep it all even. Place face down. Iron out all creases and wrinkles (This picture shows a piece that I had already folded - I just unfolded it to show you the size.)
Fold the left and right sides over, each 3 inches. Crease with iron. You now have a rectangle 4 inches by 10 inches. On the top and bottom (short sides), fold in the corners to make a point. Crease with iron.
Fold the bottom up towards the center 3 inches. Crease with iron. Do the same with the top - fold it down towards the center 3 inches. You now have a 4 inch square.
Fold a piece of tulle in half and run a stitch around 2 sides, leaving one open. You're making a 4 inch square pocket. You can do this by hand with a running stitch, but if you use a machine, it goes much faster. I talked my mom into running some up on her machine. I bought the tulle on a small roll - about 6 inches wide. I cut a piece 10 inches long.
Fill the tulle pocket with 1/2 cup of scented crushed corn cob. 1 oz FO to 2 cups cob. When I'm just doing one, I make 1/2 cup cob to 1.5 teaspoon FO. 1/2 cup might be a bit too much - adjust content so it doesn't bulge to much, but doesn't look skimpy either.
Close up pouch with running stitch. Pink the seams down so there's not so much extra material.

I've started using a 4x6 heat seal tea bag instead of sewing the tulle square. I cut one side off so it's a bit smaller than 4x4, and reseal that side with an iron. Then I fill with cob and seal the top. Much easier! Adds about .12 to the material cost.
Unfold your cotton envelope and place cob pouch in the center.
Fold the left and right sides over the cob. Secure with several small stitches near the fold where you'll be folding the top/bottom. This just helps it hang together better.
Fold over your ugliest point and secure with 5-6 stitches.
Fold over your other point and secure with 5-6 stitches.

If you use the heat seal teabag, you may be able to get away without doing any of this stitching at all.
Cut a length of ribbon. Tie it with a knot first, then tie your bow and trim the ends. This picture shows 1/8 inch ribbon - I actually prefer 1/4 inch.
Notice the ribbon goes the same direction as the folds on the back. This helps stabilize it and keep it together. Now just slip it into a 3x5 flat cello bag, secure with a blank circle label where you can write "room sachet" and the scent (or you can have them printed up of course), and stick your company label on the front.
Finished product (these were rose sachets - instructions pictured wintergreen).

Note: I used to include a hangtag inside the bag, but the FO will eventually eat the ink. I found it better to not put anything inside the bag.

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