Powder Sachet Manufacturer for Custom Stick Packs

EUPHM runs multi-lane vertical form-fill-seal equipment for stick packs, 3-side seal and 4-side seal sachets. Fill weights run from 2 g to 30 g, with most sports and nutrition powders landing between 5 g and 15 g. Line speed reaches 120,000 sachets per shift across multiple lanes. We fill single-ingredient powders and multi-component blends on the same floor, so a 4 g electrolyte stick and a 20 g protein sachet can ship in the same order. Film options include PET/AL/PE, kraft paper laminate and compostable structures, with matte, gloss or registered print finishes.

Seal integrity is checked on every run. We run peel strength and burst tests at start-up, mid-run and end-of-run, and retain samples for the shelf-life period. Stick packs are the most common format for single-serve powders because they pack flat, cut carton volume and carry a clean label panel. If your retail plan needs a carton, we can drop 10 or 30 sachets into a printed folding carton on the same line. Nitrogen flushing is available for oxygen-sensitive blends.

Powder flow, particle size and hygroscopicity decide whether a sachet fills cleanly at speed. Our formulation team reviews your blend before a pilot run and flags ingredients that bridge, cake or cling to the filler. Common fixes include adjusting carrier ratios, adding silicon dioxide at 0.5-2%, or switching a hygroscopic active to a granulated form. We can also taste-mask bitter actives with a flavour system and a sweetener blend, then run a 1,000-unit pilot so you can test the finished sachet before committing to full production.

We source and store ingredients under the same GMP system. Certificates of analysis are issued per lot, and we keep allergen segregation records for lines running dairy, soy or gluten. If your formula needs halal or vegan status, we verify supplier documents before blending, not after. Flavour and colour matching runs to a customer-approved standard, and we hold a retained reference sample for every batch. That makes repeat orders predictable, which matters when a sachet SKU starts moving on Amazon or in retail.

The plant operates under GMP and ISO 22000, with HACCP plans covering receiving, blending, filling, sealing and packing. EUPHM is an FDA-registered facility. Every sachet run carries a batch record with fill weight checks, seal test data and metal detection results. Metal detection and checkweighing run inline, and out-of-spec sachets are rejected automatically. We retain samples from each lot for the full shelf life and can supply stability data on request. Third-party lab testing for microbiology, heavy metals and label claims is available at cost.

Export documentation covers commercial invoice, packing list, certificate of origin, health certificate and certificates of analysis. We ship FOB Shenzhen or Yantian, and can quote CIF for US, EU, UK and Middle East ports. Cartons are sized to avoid wasted container space, and sachets are packed in food-grade liners inside corrugated cases. For first orders, we recommend a 1,000-unit pilot to validate fill weight, seal and flavour before the 20-35 working day mass production window. Lead times are quoted from sample approval, not from inquiry.

Every powder 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 by validated assay. Microbial testing covers total aerobic count, yeast and mould, E. coli, Salmonella and Staphylococcus aureus, with limits set to the destination market. Heavy metals are screened by ICP-MS for lead, arsenic, cadmium and mercury. For stick packs containing actives such as creatine or electrolytes, we also run disintegration and uniformity of mass checks on the first and last 20 sachets of each filling run.

Testing happens at three points: before blending, on the finished bulk powder, and on the filled sachet. The finished sachet test includes seal integrity by dye penetration and burst pressure, plus fill weight verification every 15 minutes on the line. A Certificate of Analysis is issued per batch and includes the product name, batch number, manufacturing date, expiry date, test parameters, specifications, results and the analyst and QA sign-off. We retain samples of every batch for 24 months in a temperature-controlled archive, and we keep a second set at 25°C/60% RH and 40°C/75% RH for stability monitoring.

Stability follows a standard protocol of 0, 3, 6, 12, 18 and 24 months for long-shelf-life powders, with accelerated conditions at 40°C/75% RH for 6 months. If you need a shorter launch timeline, we can provide 3-month accelerated data to support a 12-month expiry, then update the dossier as real-time data accumulates. For sachets with hygroscopic ingredients, we test moisture pick-up and caking at 30°C/65% RH to confirm the foil laminate barrier is adequate. All documentation is available in English and can be formatted for your quality team's template.

Batch records are kept for five years and include blending logs, line clearance records, fill weight charts, seal parameter traces and reconciliation of sachets, cartons and labels. If your distributor or retail customer requests a traceability exercise, we can trace a finished carton back to the raw material lot and the operator on the line within one working day. This level of documentation is standard for powder sachet manufacturing at our plant and is routinely reviewed during GMP and ISO 22000 audits.

Sachets are supplied in stick pack, 3-side seal and 4-side seal formats, with laminate structures chosen for barrier and machinability. Standard structures include PET/AL/PE for moisture and oxygen protection, and PET/PE for less sensitive powders. Stick packs are typically 20 mm to 30 mm wide and 100 mm to 160 mm long, filled from 2 g to 30 g. We can print up to 8 colours gravure or digitally, and we support matt, gloss or soft-touch finishes. For retail multipacks, sachets are cartoned in folding cartons with a tuck-end or crash-lock base, then shrink-wrapped or tray-packed for palletising.

For the US market, we set up FDA dietary-supplement labels with the required elements: statement of identity, net quantity, supplement facts panel, ingredient list, allergen declaration, and the manufacturer or distributor name and address. We also add lot code and best-by date in a legible format, typically inkjet or thermal transfer on the sachet seal and on the carton. For EU retail, we follow FIC labelling with nutrition declaration and QUID where applicable. Amazon sellers can have FNSKU labels applied to each carton or each sachet, and we can poly-bag multipacks with a suffocation warning if required.

Cartons are specified with 300 to 350 gsm FBB board, and pallets are standard 1200 x 1000 mm or 1200 x 800 mm, stretch-wrapped and corner-protected. We provide a packaging specification sheet with dimensions, board weight, print colours, barcode symbology (EAN-13 or UPC-A) and pallet pattern. If you sell through retail chains, we can run a pre-shipment packaging check against your artwork proof and issue a signed approval before mass production. This avoids the common problem of a correct formula arriving in packaging that fails a retailer's compliance review.

Sachet manufacturing for retail also requires attention to the seal area and tear notch. We place the tear notch at a consistent distance from the seal edge and test opening force on a sample of 30 sachets per batch. For stick packs, we can add a perforated tear line or a laser score. If your product is sold as a single-serve stick in a box, we can print the lot and expiry on the individual stick as well as the carton, which is often requested by pharmacy chains and club stores.

Sampling starts with a formulation brief and a target fill weight. We provide a quotation within 2 working days and, once approved, produce a sample batch in 7 to 10 working days. Samples are sent by courier with a draft COA and a packaging mock-up. If you need a pilot run before mass production, we can produce 500 to 1,000 sachets for stability and consumer testing. Mass production then runs 20 to 35 working days after sample approval, depending on laminate lead time and line scheduling. MOQ is 1,000 units per SKU, with lower thresholds for pilot runs.

For delivery, we quote EXW, FOB Shenzhen or Hong Kong, and DDP for most destination countries. Air freight is typically 5 to 8 days door to door and is suitable for samples and urgent launches; sea freight is 25 to 40 days depending on port and is more economical for full pallets. We provide a commercial invoice, packing list, bill of lading or airway bill, Certificate of Analysis, MSDS where applicable, free-sale certificate, and phytosanitary certificate for herbal ingredients where the destination requires it. All documents are issued in English and can be legalised or apostilled on request.

Production scheduling is confirmed with a written lead-time agreement after you approve the artwork and the sample. We hold a 10% overrun or underrun tolerance on sachet quantities, which is standard for vertical form-fill-seal lines. If your launch date is fixed, we can reserve line capacity with a deposit and provide weekly progress updates with photos of the first production run. For repeat orders, we keep your laminate artwork and blending records on file so that reordering is a matter of confirming quantity and delivery date.

Shipping terms are agreed before production starts. For DDP shipments, we handle import clearance and deliver to your warehouse, with duties and taxes included in the quoted price. For FOB, we deliver to the named port and provide the export declaration. We can also arrange palletisation to Amazon FBA requirements, including FNSKU labelling, poly-bagging and carton weight limits. If you need a pre-shipment inspection by a third party, we welcome it and will schedule the inspection after production is complete and before cartoning.