Stick Pack Sachet Manufacturer for Powder and Liquid Formats

Our vertical form-fill-seal lines run 4-lane and 6-lane configurations. Fill accuracy is held to ±2% for powders above 5 g and ±3% for fine granules below 2 g. We use servo-driven auger and volumetric cup fillers, depending on flowability. Seal pressure and temperature are logged per lane, and every roll of film is inspected for width, thickness and sealant layer before loading.

Changeover between stick widths takes 45-90 minutes, including former replacement and validation of three test sachets. We run 24-hour campaigns for large orders, with inline checkweighers rejecting out-of-tolerance sticks. Metal detection and X-ray inspection are available for high-risk powder blends. Waste film from setup and rejects is weighed and reported per batch.

We formulate for flowability, hygroscopicity and taste. Common bases include maltodextrin, inulin, erythritol and gum Arabic. For liquid stick packs, we adjust viscosity with glycerin or propylene glycol to keep fill weight consistent. Flavours, sweeteners and colours are dosed by weight, not volume, to maintain batch-to-batch consistency. We can match a reference sample or develop from a brief.

Ingredient sourcing covers vitamins, minerals, amino acids, botanical extracts and probiotics. We hold documentation for allergen control, non-GMO status and country of origin. For vegan claims, we use certified supply chains and segregate production runs. Stability testing at 25°C/60% RH and 40°C/75% RH runs for 3-6 months, with real-time data available on request.

The plant is GMP-certified and holds ISO 22000 and HACCP. Halal certificates are current for relevant lines. We are an FDA-registered facility for US-bound products. Batch records, certificates of analysis and raw material traceability are prepared for each order. Retain samples are kept for 24 months. Third-party lab testing covers heavy metals, microbiology and label claim verification.

Shipping is arranged from Shenzhen or Hong Kong. We prepare commercial invoices, packing lists, certificates of origin and health certificates. For the EU and UK, we provide statements on novel food status where applicable. Air freight takes 5-8 days to major hubs; sea freight 18-28 days. Cartons are sized for retail and e-commerce, with stick packs counted in 10s, 20s or 30s per carton.

Every stick pack batch is sampled at three points: incoming raw materials, in-process fill weight, and finished goods. Identity testing by FTIR confirms each active ingredient against a reference spectrum. Potency assays by HPLC or titration verify label claim within 95.0 to 105.0 percent. Microbial testing covers total aerobic count, yeast and mould, E. coli, and Salmonella, with results available within 5 to 7 working days. Heavy metals (lead, arsenic, cadmium, mercury) are tested by ICP-MS against EU and US pharmacopoeial limits. Disintegration testing applies to stick packs containing tablet blends or compressed granules, ensuring the powder disperses within 3 minutes in water at 37°C.

A Certificate of Analysis (COA) is issued per batch and includes: product name, lot number, manufacture and expiry dates, fill weight range, active ingredient assay results, microbial counts, heavy metals results, and a statement of conformity to the agreed specification. We retain samples from every batch for 24 months at 25°C/60% RH and 40°C/75% RH for accelerated stability. Stability protocols follow ICH Q1A(R2) guidelines, with testing at 0, 3, 6, 12, and 24 months for long-term conditions and 0, 1, 2, 3, and 6 months for accelerated. A full stability report is provided after 6 months of accelerated data, which is sufficient for most markets to assign a 24-month shelf life.

In-process controls run every 30 minutes on each filling lane. Fill weight is checked against a target of ±3 percent, seal integrity is verified by dye penetration at 0.5 bar for 30 seconds, and headspace oxygen is measured for nitrogen-flushed packs to confirm below 2 percent residual oxygen. Any deviation triggers a line stop and re-validation. Batch records are retained for 5 years and are available for audit by the brand owner or a third-party inspector. We do not release any batch without a completed and signed batch record, a passing COA, and a retained sample in storage.

Stick packs are formatted for retail in several ways. Primary options include single stick packs in a printed carton, stick packs in a flat pouch or sachet, and stick packs in a composite canister. We also offer stick packs in a display-ready case for club stores. Secondary packaging can include a bottle or blister pack if the stick pack is part of a kit. Film structures are selected for barrier properties: standard PET/AL/PE for moisture and oxygen protection, or PET/PE for cost-sensitive powders. We print up to 8 colours rotogravure or flexo, with registration tolerance of ±0.3 mm. For liquid stick packs, we use a PET/AL/PE structure with a spout or tear notch.

Labels must comply with the US FDA dietary supplement labelling requirements if the product is sold in the United States. This includes: a supplement facts panel with serving size, amount per serving, and percent daily value where applicable; a list of ingredients by common name; allergen declarations; and a statement of identity. We can generate a label proof for your review, but final responsibility for label compliance rests with the brand owner. We also support Amazon FNSKU labelling, poly-bagging with a suffocation warning, and retail-ready carton markings. Lot and expiry coding is applied by inkjet or laser on the stick pack itself, with a minimum character height of 2 mm, and on the carton.

Carton specifications are agreed per SKU: typical dimensions are 200 x 120 x 80 mm for a 30-stick carton, with a 1.5 mm greyboard and a printed wrap. Pallets are standard 1200 x 1000 mm or 1200 x 800 mm, with a maximum load height of 1.8 m and a maximum weight of 1,000 kg. We use stretch wrap and edge protectors for export. For Amazon FBA, we can apply FNSKU labels and pack in poly bags with a suffocation warning. We do not provide retail packaging design services, but we can work with your designer to ensure dieline compatibility and print-ready files.

Sampling starts with a formulation brief and film specification. We provide a formulation sample and a film sample within 7 to 10 working days. If a new formulation requires stability testing, add 4 to 6 weeks for accelerated data. Sample costs are quoted per project and are credited against the first mass-production order. Mass production begins after sample approval and a 30 percent deposit. The production window is 20 to 35 working days, depending on raw material lead times and line availability. We schedule stick pack lines in 4-lane and 6-lane configurations, with a minimum run of 1,000 units per SKU. Pilot runs from 1,000 units are available for market testing.

We ship under EXW, FOB, or DDP terms. EXW means you collect from our Guangdong factory. FOB applies to Shenzhen or Hong Kong port, with loading and export clearance included. DDP covers delivery to your door, with duties and taxes paid, and is available for most major markets. Air freight is typically 5 to 7 days door-to-door for urgent orders, while sea freight is 25 to 35 days to Europe or the US West Coast. We provide a packing list, commercial invoice, and bill of lading for each shipment. For air freight, we provide an air waybill and a security declaration if required.

Documentation provided with each shipment includes: Certificate of Analysis (COA), Material Safety Data Sheet (MSDS) for liquid or gel products, and a free-sale certificate issued by the local authority. For products containing botanical ingredients, a phytosanitary certificate is provided where required by the destination country. We also provide a certificate of origin for customs purposes. All documents are issued in English and can be legalised or apostilled upon request. We recommend confirming import requirements with your customs broker before production, as some markets require additional registration or notification for dietary supplements.