Effervescent Sachet Manufacturer for Stick Pack Supplements

Our sachet line runs vertical form-fill-seal equipment with a rated output of 40–60 sticks per minute, depending on granule flow and stick width. That translates to roughly 18,000–28,000 sachets per shift. We run 5–7 days a week, so a 100,000-unit order typically books 4–6 production days once granules are released. Fill accuracy holds within ±3% on a 2,000 mg target.

Stick packs are sealed on all four edges with a tear notch 8–10 mm from the top. We can print lot number and best-before date inline, or leave the film blank for a label. Standard film is 3-layer PET/AL/PE for moisture barrier; clear or white PET/PE is available where aluminium is not wanted. Nitrogen flushing is optional for oxidation-sensitive actives.

A sachet granule needs to dissolve in 150–200 ml of water in under 60 seconds, without the grit that comes from poor acid-alkali balance. We typically use citric acid and sodium bicarbonate at a 1:1.2 to 1:1.5 ratio, then adjust with sodium carbonate for a faster finish. Actives above 30% of the granule weight can slow dissolution, so we test each formula before scale-up.

Sweetener systems matter more in a sachet than in a tablet. We work with sucralose, stevia (Reb A 97%), erythritol and monk fruit, alone or blended. Flavours are spray-dried or liquid, dosed at 0.5–2.5%. Colour can be natural (beetroot, spirulina) or synthetic. We avoid sodium benzoate and artificial colours where the target market’s labelling rules make them a liability.

Every sachet batch is checked for fill weight (20 sticks sampled per lot), seal integrity, moisture content (target below 2.5%), pH of the reconstituted drink, and dissolution time. We hold retained samples for 24 months. The facility is GMP-certified, ISO 22000 and HACCP compliant, and FDA-registered. Halal certificates are available on request, and vegan claims can be supported where the supply chain allows.

For export we prepare the documents buyers in the US, EU, UK and Middle East need: certificate of analysis, certificate of free sale, ingredient and allergen statements, nutritional panel data, and stability data at 25°C/60% RH and 40°C/75% RH. We ship FOB Shenzhen or Yantian, with air freight for samples. Carton configuration is 20–50 sachets per box, 24–48 boxes per carton.

Every batch of effervescent sachets is tested at three points: incoming raw materials, in-process granules, and finished sticks. Identity and potency are confirmed by HPLC or titration for actives such as vitamin C, electrolytes, and collagen peptides. Microbial testing covers total aerobic count, yeast and mould, E. coli, and Salmonella, with results available within 5 working days. Heavy metals (lead, arsenic, cadmium, mercury) are screened by ICP-MS against EU and US pharmacopoeial limits. Disintegration testing follows a modified method for sachets: one stick is dissolved in 200 ml of water at 20°C, and the solution must clear within 60 seconds with no visible residue.

Each batch receives a certificate of analysis (COA) that lists the product name, batch number, manufacturing date, expiry date, fill weight range, assay results for each active, microbial counts, heavy metal results, and disintegration time. The COA is issued in English and can be translated into other languages on request. Retention samples of every batch are kept for 24 months at 25°C/60% RH and 40°C/75% RH, with a 12-month accelerated stability protocol that includes moisture, potency, and dissolution checks at 0, 3, 6, 9, and 12 months. This data supports shelf-life claims of up to 24 months when stored below 25°C and away from direct sunlight.

In-process controls during sachet filling include fill weight checks every 15 minutes using a calibrated balance, seal strength testing by tensile tester at 120–160°C sealing temperature, and visual inspection for seal integrity and print registration. Any deviation beyond 2% of target fill weight triggers line adjustment and re-testing. Finished sachets are sampled per AQL 2.5 for critical defects and AQL 4.0 for major defects. All QC records are retained for 5 years and are available for audit by the brand owner or their nominated third party.

Effervescent sachets are typically packed as stick packs in a box or pouch, but we also offer four-side-seal sachets and blister-style single-dose packs. Stick packs are 20–30 mm wide and can be printed with up to 8 colours on the film. Secondary packaging options include cartons with a tuck-in or tear-strip opening, doypacks with zipper, and composite cans. For US retail, we print FDA dietary supplement label elements: statement of identity, net quantity, supplement facts panel, ingredient list, allergen declaration, and the required ‘Keep out of reach of children’ and ‘Do not use if seal is broken’ warnings. We also include lot number and expiry date in a legible format, typically inkjet-printed on the stick and carton.

Carton specifications are tailored to retail channel requirements. Standard cartons use 350 gsm greyboard with matt or gloss lamination, and we can add a security seal or tamper-evident band. Pallet configuration is customised: typical cartons are packed 12 or 24 sticks per box, then 24 or 48 boxes per shipper, with a maximum pallet height of 1.8 m and stretch-wrap plus corner boards for export. We provide dieline templates and can arrange pre-production samples for retail buyer approval. For Amazon FNSKU compliance, we apply the FNSKU label to each unit and can poly-bag units with a suffocation warning if required. We do not print FNSKU labels without written authorisation from the brand owner.

Label artwork is checked against the target market regulations before printing. For the EU, we include the nutrition declaration, botanical names, and allergen information in the local language. For the Middle East, we add Arabic labelling and halal certification marks where applicable. We maintain a library of approved packaging materials and can source recycled or recyclable films on request. All packaging components are food-grade and meet EU 10/2011 and FDA 21 CFR 174-186 requirements. We provide a packaging specification sheet with each order, listing material, dimensions, print colours, and barcode symbology.

The minimum order quantity for effervescent sachets is 1,000 units per SKU, with pilot volumes discussed case by case. Samples are produced within 7–10 working days after formula and packaging approval, and we ship them by courier at the brand owner’s expense. Mass production takes 20–35 working days after artwork approval, depending on the number of SKUs and the complexity of the formulation. We provide a production schedule with milestone dates and share progress photos at the granulation, filling, and packing stages.

For delivery, we offer EXW, FOB, and DDP Incoterms. FOB shipments depart from Shenzhen or Hong Kong ports, with sea freight to the US taking 18–25 days and to Europe 22–30 days. Air freight is available for urgent orders at a higher cost, typically 5–8 days door-to-door. We provide a full set of shipping documents: commercial invoice, packing list, bill of lading or airway bill, certificate of origin, COA, MSDS, and a free-sale certificate. For products containing botanical ingredients, a phytosanitary certificate can be arranged if the destination country requires it. We also assist with customs clearance by providing the HS code and necessary product information.

Payment terms are 50% deposit with the balance against a copy of the bill of lading, or a letter of credit for larger orders. We recommend booking sea freight at least 4 weeks before the required delivery date to avoid peak-season surcharges. For DDP shipments, we handle import clearance and duties, and deliver to the brand owner’s warehouse. All shipments are palletised and stretch-wrapped, with a packing list attached to each pallet. We can also arrange insurance on request.