Packaging Resource Hub for Supplement Brands

Standard formats are HDPE and PET bottles from 30 ml to 500 ml, doypack pouches from 100 g to 1,000 g, and PVC or PVDC blister packs at 10 to 30 cavities per card. Bottle filling runs at 2,400 to 6,000 units per hour depending on count and closure. Pouch lines handle 1,200 to 1,000 units per hour. Blister tooling is cut per SKU, so it suits runs above 10,000 units. All lines run in a temperature-controlled hall held at 18-24 degrees Celsius and below 45 percent relative humidity.

Tooling and mould costs are quoted separately and amortised across the order. A 200 ml bottle mould set typically adds 3-5 working days before filling starts. Pouch formats with a zipper or spout need a die-cut plate; allow 5-7 days. If you are testing a market, start with a stock bottle and a printed label rather than custom tooling. That keeps the first run at 1,000 units and avoids a five-figure tooling spend before you have sell-through data.

Capsules are filled at 300-1,200 mg in sizes 0 to 3, with vegetarian HPMC or bovine gelatin shells. Powders run 100-1,000 g per pouch or tub. Liquids and softgels are filled at 30-500 ml. Closures include induction-sealed screw caps, child-resistant caps to US 16 CFR 1700.20, and flip-top lids. Desiccant sachets or silica canisters are added for hygroscopic powders. Nitrogen flushing is available for oils and probiotics to hold shelf life at 18-24 months.

Labels carry the mandatory panel set for your market: supplement facts or nutrition declaration, allergen statement, batch code, best-before date, and country of origin. We print on coated paper, PP or PET with matte or gloss lamination. Variable data is applied inline, so batch and date codes are not a separate pass. Artwork files should be supplied as AI or PDF with 3 mm bleed and fonts outlined. First article labels are approved before the full run to avoid reprints.

Every batch is released against a certificate of analysis covering identity, assay, microbial limits, heavy metals and residual solvents where relevant. The plant holds GMP, ISO 22000 and HACCP. halal and vegan claims are supported by certificates on file and can be listed on the label. Stability testing runs at 25 degrees Celsius and 60 percent relative humidity for 24 months, with accelerated data at 40 degrees Celsius and 75 percent relative humidity for 6 months. Shelf life is set from that data.

Shipping documents include commercial invoice, packing list, certificate of origin and, where required, health certificate and free sale certificate. FOB Shenzhen or Yantian is standard; CIF and DDP are quoted on request. Cartons are 5-ply with a 25 kg maximum, palletised to 1.2 m by 1.0 m and stretch-wrapped. Air freight samples leave within 3 working days of release. Sea freight to Rotterdam runs 28-35 days, to Los Angeles 18-24 days, and to Jebel Ali 22-28 days.

Every packaging batch is tied to a retained bulk lot with its own analytical record. Before filling, we verify identity and potency by HPLC or UV against the approved specification, and screen for microbials (total plate count, yeast and mould, E. coli, Salmonella) and heavy metals (lead, arsenic, cadmium, mercury). Disintegration testing is run on capsule and tablet formats to confirm the finished unit meets the stated release profile. Results are logged against the batch number that appears on the bottle, so the retail unit can be traced back to the bulk lot and the incoming raw material.

Testing happens at three points: incoming raw material, bulk blend before encapsulation or filling, and finished packaged goods. The finished-goods check covers appearance, fill weight, seal integrity and label accuracy, including lot and expiry coding. Where a customer supplies a specification, we test to that limit rather than our default. Any out-of-spec result holds the batch and triggers a deviation report before release. We do not ship a batch until the certificate of analysis is signed off by the QC lead.

The certificate of analysis lists the product name, batch number, manufacture and expiry dates, the tests performed, the specification limits, the results and the method used for each test. It is issued per batch, not per order, so a multi-batch shipment carries multiple COAs. Customers who need a summary sheet for their own QA file can request a batch record extract covering fill weights and line checks. We retain samples of every batch for the shelf life plus twelve months, stored under the same conditions as the commercial stock.

Stability follows a bracketed protocol: accelerated conditions at 40°C and 75% relative humidity for six months, with real-time data at 25°C and 60% relative humidity running in parallel. Where a customer needs a specific claimed shelf life, we open a stability lot at the packaging stage and test at 0, 3, 6, 12, 18 and 24 months for potency, microbials and appearance. The resulting data supports the expiry date printed on the label and can be shared under confidentiality for regulatory filings.

Container options cover HDPE bottles from 60 ml to 500 ml, PET jars for powders, blister packs for tablets and capsules, and stick packs or sachets for single-serve powders. Closure choices include standard screw caps, induction seals, child-resistant push-turn caps and tamper-evident bands. Desiccant canisters or sachets are added where the formula is moisture-sensitive. Label stock is chosen for the retail channel: paper for dry environments, synthetic for chilled or humid conditions, and clear film where a no-label look is wanted.

For the US market, labels carry the statement of identity, net quantity, supplement facts panel, other ingredients, suggested use, and the name and place of business of the distributor. We set the font sizes for the supplement facts panel to the current FDA format and check that the serving size matches the fill weight. Allergen statements and 'contains' lines are placed per the customer's market rules. Lot number and expiry date are inkjet-coded on the bottle and the carton, with the format agreed at artwork approval so the two always match.

Cartons are specified by board grade, print method and pallet pattern. A standard shipper holds 12, 24 or 48 retail units depending on bottle size, and we confirm the pallet count per layer and per pallet before production so the freight quote is accurate. For Amazon sellers, we can apply FNSKU labels, poly-bag units where required, and print the carton dimensions and weight on the shipping mark. Retail compliance checks cover barcode scannability, carton drop testing and label placement against the approved artwork proof.

Artwork goes through a pre-press proof that the customer signs before plates are made. We check barcodes against the GTIN database, confirm the nutrition or supplement facts values against the formula, and flag any claim that needs substantiation in the target market. Once approved, the artwork revision is locked to the purchase order. Changes after plate-making carry a setup cost and add roughly five working days to the schedule, so it is worth resolving label text before the deposit is paid.

The sample timeline starts with a stock-format sample, which ships in 7 to 10 working days and includes the container, closure and a printed label mock-up. A custom-printed sample requires artwork approval first and adds about 10 working days for plate-making and a short run. Samples are sent by courier with a tracking number, and the freight is charged at cost. We recommend approving the physical sample before placing the bulk order, because colour and cap fit are easier to judge in hand than on a screen.

Mass production runs 20 to 35 working days after sample and artwork approval, counted from the day the deposit clears and the packaging materials arrive at the line. Bottles and cartons are ordered against the confirmed PO, and a delay in artwork sign-off moves the whole schedule. For pilot quantities from 500 units, the window is shorter but depends on whether the format is stock or custom. We give a written production schedule with the order confirmation so the customer can plan the freight booking.

Air freight suits pilot and launch volumes and takes about 5 to 8 days door to door, while sea freight for full pallets takes 25 to 40 days depending on the destination port. We quote EXW, FOB Shenzhen or Hong Kong, and DDP where the customer wants a landed cost. The commercial invoice, packing list and bill of lading are issued with each shipment. A certificate of analysis, safety data sheet where relevant, free-sale certificate and, for plant-derived ingredients, a phytosanitary certificate can be provided on request.