Electrolytes Sachet Manufacturer for Retail and Private Label

EUPHM fills electrolyte sachets on multi-lane stick-pack lines. Standard stick dimensions run 20 mm to 30 mm wide and 90 mm to 120 mm long, which covers 3 g to 10 g of powder. We run 3-side seal and 4-side seal formats, with or without a tear notch. Film structures include PET/AL/PE for moisture barrier, PET/PE for cost-sensitive runs, and compostable or recyclable mono-material options where the brand requires them. Fill accuracy is held to plus or minus 2 percent on target weight.

Line capacity supports 500,000 to 1,500,000 sachets per month depending on format and order size. Secondary packaging covers single sticks, 6-count and 10-count cartons, and 30-count display boxes. EUPHM also runs multi-flavour variety packs, where each stick carries a different SKU code and the outer carton is packed to a fixed ratio. For brands launching on Amazon or in pharmacy chains, we can print lot codes and expiry dates on the stick itself, not only the carton.

A working electrolyte sachet balances sodium, potassium, magnesium and chloride against a carrier that dissolves fast and does not settle. Typical sodium sources are sodium citrate, sodium chloride and sodium bicarbonate. Potassium comes from potassium citrate or potassium chloride. Magnesium is usually magnesium citrate, magnesium glycinate or magnesium malate. We adjust the ratio to the claim the brand wants to make: exercise hydration, fasting support, keto, travel rehydration or paediatric use.

Carbohydrate content can be zero, low or full-sugar. Zero-sugar versions use stevia, monk fruit or sucralose, and we run sensory panels to check bitterness and aftertaste. Flavours are available as natural, nature-identical or organic-certified. Where the label needs organic status, we source and EU-organic compliant raw materials and hold the certificate chain. EUPHM can also add vitamin C, B-complex, zinc, taurine or caffeine, provided the combined blend stays free-flowing and within the fill weight of the stick.

Every electrolyte batch is tested for fill weight, moisture content, dissolution time and microbial load. We run incoming raw material checks, in-process checks every 30 minutes during filling, and finished goods testing before release. Heavy metals, lead, arsenic, cadmium and mercury are tested against EU and US limits. Certificates of analysis are issued per batch. The facility is GMP-certified and operates under ISO 22000 and HACCP. Halal certification is available on request for Middle East and Israel-bound orders.

Export documentation covers US, EU, UK and Middle East markets. EUPHM provides commercial invoice, packing list, certificate of origin, health certificate and, where required, FDA prior notice support for US-bound shipments. The facility is FDA-registered. Cartons are packed to ISTA-1A standard for parcel and pallet shipping. Air freight from Guangdong to Los Angeles takes 5-8 days; sea freight to Rotterdam runs 28-35 days. We ship FOB, CIF or DDP depending on the buyer's customs setup.

Every electrolyte sachet batch is tested against a written specification before release. Incoming raw materials are sampled at 100% of containers for identity by FTIR or HPLC, and potency is confirmed for actives such as sodium citrate, potassium chloride and magnesium citrate. Microbial testing covers total aerobic count, yeast and mould, E. coli and Salmonella, with limits set to the stricter of the destination market or the customer's own specification. Heavy metals (lead, arsenic, cadmium, mercury) are screened by ICP-MS on each lot of mineral salts, and the finished powder is checked for uniformity and dissolution time in water at 20°C and 37°C.

In-process checks run at the start, middle and end of each filling shift. Fill weight is verified every 30 minutes on a calibrated checkweigher, seal integrity is tested by dye penetration and burst pressure, and sachet length and width are measured against the artwork drawing. A retained sample of 30 sachets per batch is held for 24 months at ambient conditions, with an accelerated stability arm at 40°C/75% RH for 3 months to support a 24-month shelf life claim. A Certificate of Analysis is issued per batch and includes lot number, fill weight range, assay results, microbial counts, heavy metals and seal test data.

Stability protocols follow ICH Q1A principles adapted for food-supplement powders. If you need a 24-month expiry, we run real-time data at 25°C/60% RH and 30°C/65% RH for the ASEAN and Middle East markets, with 0, 3, 6, 12, 18 and 24-month pull points. For a shorter development timeline, 3-month accelerated data can support a 12-month initial claim while real-time data accumulates. The stability plan is agreed before the first production run so that the pull points align with your retail launch date.

Electrolyte sachets are typically packed in a folding carton of 10, 20 or 30 sticks, with a printed inner leaflet or a QR code to a digital label. Carton board is 300-350 gsm with matt or gloss lamination, and each carton carries a lot code and expiry date applied by inkjet or thermal transfer at the filling line. For Amazon and retail compliance, we can print the FNSKU and box dimensions on the carton and apply a 2D DataMatrix code that links to the batch record. Stick artwork is printed on the film by rotogravure in up to 8 colours, with a tear notch positioned 8-10 mm from the top seal.

For the US market, the label must include the Supplement Facts panel, serving size, amount per serving, percent daily value where applicable, other ingredients, and the manufacturer or distributor address. We prepare the artwork to your approved label text and check that the net quantity, allergen statements and storage instructions are present. For the EU, the nutrition declaration and the permitted health claims are checked against Regulation 1924/2006 before print. We do not write claims for you, but we flag any claim that is not supported by the formulation or that would need a novel food assessment.

Cartons are packed 12 or 24 per shipper, with a maximum shipper weight of 15 kg for manual handling. Pallets are 1,200 x 800 mm or 1,200 x 1,000 mm, stretch-wrapped and corner-protected, with 1,000-1,200 kg per pallet depending on carton size. For Amazon FBA, we can print and apply FNSKU labels and pack to the 25-inch or 25-kg carton limit. We also provide a packaging specification sheet with dimensions, board grade, print colours and barcode symbology so your retail compliance team can approve before mass production.

Sampling starts with a formulation brief and a target fill weight. We provide a quotation within 2 working days and, once the formula is agreed, a sample of 50-100 sachets in 7-10 working days. The sample includes a draft COA and a packaging mock-up. If you need a stability sample, add 3-4 weeks for the accelerated arm. Sample costs are credited against the first mass-production order above 10,000 units. For a pilot run, the MOQ can drop to 1,000 units per SKU, but the unit cost is higher because of film printing set-up.

Mass production runs 20-35 working days after sample approval and receipt of the deposit. That window includes film printing (10-15 days), powder blending and filling (5-7 days), and secondary packaging and QC release (3-5 days). If you supply your own printed film, the production window can shorten to 15-20 days. We schedule filling lines in 8-hour shifts and can add a second shift for orders above 50,000 sachets, subject to film availability. We confirm the ship date in writing before the deposit is paid.

We ship by air for orders under 500 kg and by sea for larger volumes. Air freight to the US or EU takes 5-8 days door to door, while sea freight takes 28-35 days to the US West Coast and 30-38 days to Northern Europe, plus customs clearance. We quote EXW, FOB Shenzhen or Hong Kong, and DDP for Amazon FBA or a named warehouse. Documents provided include the commercial invoice, packing list, COA per batch, MSDS, free-sale certificate, and a phytosanitary certificate where the destination requires it for plant-derived ingredients. We do not provide a certificate of origin unless requested at quotation.