Prebiotics Sachet Manufacturer for Custom Stick Pack Formulas

Prebiotic fibres are not all the same on a sachet line. Inulin and FOS are fine, static-prone and hygroscopic. GOS syrups need a carrier. Resistant dextrin flows well but can bridge in the hopper. Our four vertical form-fill-seal lines run auger and volumetric fillers with dehumidified dosing zones. We hold fill weight to ±3% at 2g to 10g, which keeps label claims accurate and reduces giveaway.

Each line runs at 40-60 cycles per minute. That gives a practical output of 180,000 sachets per day across four lines, or roughly 3.6 million per month on a single shift. We run 24-hour operations when a launch window is tight. Film is supplied as 3-ply or 4-ply laminate with a tear notch and a 5mm seal. Stick packs can be printed up to 8 colours, or left plain for a label-applied finish.

Prebiotic sachets often combine two or more fibres with a flavour system and a sweetener. We work with inulin (chicory root), FOS, GOS, resistant dextrin, partially hydrolysed guar gum (PHGG), acacia fibre and beta-glucan. Typical inclusion rates are 3g to 5g of fibre per sachet. If the dose is higher, we adjust the carrier or split the serving across two sachets.

Flavour and mouthfeel matter more than buyers expect. Inulin has a mild sweetness and a slight body. GOS is less sweet. Resistant dextrin is close to neutral. We can add natural flavours, citric acid, monk fruit, stevia or sucralose, and a small amount of silicon dioxide or tricalcium phosphate to stop caking. For organic-certified projects, every input must be on the approved list before we start sampling.

Every batch of prebiotic sachets is tested for fill weight, seal strength, moisture content and microbiological limits. We hold raw material COAs, in-process records and finished product COAs for three years. The facility is GMP, ISO 22000 and HACCP certified. If you need halal or vegan certification, we arrange it through the relevant body and keep the certificate on file for your market.

For export, we prepare commercial invoice, packing list, certificate of origin, health certificate, and halal certificates where applicable. Sachets are packed into cartons or display boxes. We ship FOB Shenzhen or Yantian, or arrange air freight for pilot runs. Lead time for documents is 3-5 working days after production. We do not claim FDA approval; the facility is FDA-registered where that registration is relevant to your import file.

Every prebiotic sachet batch is tested against a written specification before release. Incoming raw materials are checked for identity by FTIR against a reference spectrum, and fibre assay is run to confirm the declared purity of inulin, FOS, GOS, resistant dextrin or PHGG. Microbial testing covers total aerobic count, yeast and mould, E. coli, Salmonella and Staphylococcus aureus. Heavy metals are screened by ICP-MS for lead, arsenic, cadmium and mercury against the limits set by the destination market. Where a blend includes a probiotic or enzyme component, potency is assayed at release and again at shelf-life end.

In-process checks run on each stick pack line at start-up, every 30 minutes and at line stop. Operators verify fill weight on a calibrated balance, seal integrity by dye penetration and visual seal inspection, and lot code legibility. A Certificate of Analysis is issued with each batch and lists the product name, batch number, manufacturing date, expiry date, tests performed, specification limits, results and the releasing QA signature. Retention samples of the finished sachet, the bulk powder and each raw material lot are held for the full shelf life plus 12 months.

Stability follows a defined protocol. Accelerated testing at 40 degrees Celsius and 75 percent relative humidity runs for six months with pulls at zero, one, three and six months. Real-time testing at 25 degrees Celsius and 60 percent relative humidity runs for the declared shelf life with pulls every three months. Tests cover appearance, moisture content, fibre assay, microbial count and seal strength. If you need a specific shelf-life claim for a retail listing, we can run a dedicated stability study before commercial production and share the raw data with your QA team.

The primary format is a three-side-seal or four-side-seal stick pack in laminated film, typically PET, aluminium and polyethylene at 90 to 120 microns, with a tear notch and optional laser scoring. Films can be supplied with a registered matte or gloss finish and up to eight colours. Secondary packaging options include a folding carton holding 10, 20 or 30 sachets, a stand-up pouch with a resealable zipper, or a rigid bottle for powder formats. We can also run blister packs where a tablet or capsule line is the chosen delivery form.

For the US market, we set up the label to the FDA dietary supplement requirements: statement of identity, net quantity, supplement facts panel with serving size and percent daily value, ingredient list in descending order of weight, and the required allergen and advisory statements. Lot number and best-before date are inkjet coded on the sachet, the carton and the shipping case, with the same code across all three levels so a recall can be traced from any point. We do not print health claims without your written substantiation and sign-off.

Cartons are specified to your retail channel. A standard export carton holds 60 to 120 sachets depending on stick size, with dimensions and gross weight confirmed at artwork approval. Pallet configuration uses a 1200 by 1000 millimetre pallet, shrink-wrapped and corner-boarded, with a maximum stacked height of 1.8 metres for sea freight. For Amazon sellers, we apply the FNSKU barcode to each unit and the box, print the FBA box label, and follow the poly-bag and suffocation-warning rules where loose sachets are packed. Retail compliance checks for barcode scannability and carton drop testing are done on the first production run.

The sample process starts with a formulation brief and a signed specification. We issue a quotation within two working days, then produce a pilot sample in 7 to 10 working days for standard fibre blends, or up to 15 working days where a new film print or a custom flavour system is involved. Samples are sent by courier with a draft COA. Once you approve the sample and the artwork, we lock the batch record and schedule production. Mass production runs 20 to 35 working days depending on fill weight, film lead time and whether the raw material is in stock.

Minimum order quantity is 1,000 units per SKU for retail-ready sachets and 1,000 units for pilot runs. Pilot runs use the same lines as mass production, so the fill weight and seal quality you approve are the ones you receive at scale. We hold safety stock of common prebiotic fibres so that repeat orders can start production within five working days of a purchase order, subject to film availability.

Shipping is arranged on EXW, FOB Shenzhen or Hong Kong, or DDP to your warehouse. Air freight takes 5 to 10 days door to door and suits pilot runs and urgent retail launches; sea freight takes 25 to 40 days port to port and is the default for full container loads. Documents issued with each shipment include the commercial invoice, packing list, Certificate of Analysis, material safety data sheet, free-sale certificate and, where the destination requires it, a phytosanitary certificate and certificate of origin. We can also provide a halal certificate on request where the ingredient and line status allow.