Your product may be ready for filling. But that does not mean it can go straight into the machine.
When a product comes to us, we first ask: Is it a cream, a gel or a liquid? How much is needed for a single use? Where and how will the user open the sachet?
If these questions are not answered clearly, filling can still take place, but the resulting format may not suit your customer’s use. For example, if a tester contains too little for a single trial, it will not provide the experience you intended.
Our first step is to understand the product and its intended use. We then evaluate the fill quantity and packaging expectations together.
For related information, read our tester sachet fill quantity guide, see an example of a 5 ml sachet product, or contact RENASAN to discuss your requirements.
What information is needed before sachet filling begins?
Having a finished cream, gel or liquid formulation does not automatically establish which sachet structure or filling process is appropriate. The first task is to identify the product accurately, understand its intended application and define the experience the customer should receive. Planning without considering both formulation behavior and packaging expectations can cause changes during sampling or full production.
Two products filled to the same weight can have different viscosities, dispense differently and serve different purposes. Pouch geometry, opening design and the characteristics of the inner packaging surface influence handling as well. Instead of beginning with only “we need individual sachets,” prepare a product information brief that enables a technical feasibility discussion.
Product identity and allocation of responsibilities
The brand owner should provide clear information about the formulation’s identity, intended use, handling and storage needs, and any known packaging restrictions or compatibility requirements. The filling partner evaluates whether the requested operation can be performed and what is included in its scope. Responsibility for sourcing materials, approving artwork, setting quality criteria and releasing finished goods should be documented.
These responsibilities vary depending on the formulation and contractual arrangement. General sachet-filling guidance is not enough to establish compliance for a specific cosmetic, hygiene or other product category. Appropriate technical and regulatory assessments must be based on the actual item and destination market.
A useful pre-filling product brief
| Topic | Information to define |
|---|---|
| Product identity | Name, code, batch reference and document revision |
| Formulation type | Cream, gel, liquid or other relevant processing description |
| Intended use | Single trial, single application or another use pattern |
| Target fill | Net weight or volume with an approval method |
| Packaging | Sachet size, material construction and opening style |
| Artwork | Approved text, language, batch/date fields and file version |
| Storage | Specified temperature and other handling conditions |
| Logistics | Target quantity, carton configuration and dispatch plan |
This is a starting framework, not an exhaustive specification. Depending on the product, stability, compatibility, quality and traceability studies may also be required. Critical missing information should be resolved explicitly rather than filled in by assumption.
Consistency and process suitability
Viscosity affects how a formulation flows and may influence the filling technology or operating conditions. Foaming, particulate matter, temperature sensitivity and changes in flow behavior can also matter for some products. A label such as “gel” or “cream” alone does not demonstrate machine compatibility.
A small-scale filling trial may therefore be appropriate. Such an assessment can examine net-fill control, pouch formation, seal integrity, leakage and opening behavior. Any required longer-term packaging compatibility or product stability work must be considered separately: a successful short trial does not establish a complete shelf-life claim.
Define the quantity around the intended experience
For tester sachets, the end-user experience is central to choosing a quantity. A single-application sample differs from one designed for repeated use. Consider how much product can actually be dispensed, whether the opening process causes losses and whether the sample permits the intended use. Our article about choosing a tester sachet fill quantity explores these factors in more detail.
Do not determine pouch dimensions independently from the fill target. Sealing area, product distribution inside the pack and ease of emptying must all be considered. Increasing the fill weight is not always beneficial, however: material consumption and campaign economics also matter.
Packaging material and sealing
Compatibility between the product and the sachet film or multilayer laminate needs attention before a production commitment is made. Barrier requirements, mechanical strength, printability and sealing behavior vary with formulation and intended shelf life. Do not assume a generic pouch material is suitable for every product.
Storage period and handling conditions also influence packaging requirements. Relevant data sheets and, where necessary, validation work should support decisions. Easy opening, controlled dispensing and accurate label information matter to the consumer independently of the packaging’s technical barrier properties.
Artwork, labeling and traceability
Sachet printing is not merely a visual design decision. Product identity, relevant directions, required warnings, lot-tracking fields and other information may have to be planned. Exact labeling requirements depend on the product classification and where it is sold. Printing unapproved copy can lead to avoidable rework, delays or unusable packaging inventory.
Our guide to clear product specifications and revision control describes how to manage approved artwork alongside product information. A controlled file version should remain linked to the production order.
From feasibility to a production order
A practical workflow begins with information gathering and a technical feasibility review, followed by sample development where needed, commercial quotation and formal approval. The approved sample and operating assumptions should be identified before routine production starts. Lead-time planning must account for relevant material sourcing, printing and other preparation steps.
Looking only at the price of filling labor can hide other cost drivers. When product details and approval responsibilities are specified clearly, it becomes easier to identify the work included and reduce the risk of incorrect packaging or preventable rework.
Frequently asked questions
Can any ready-made product go straight into a sachet?
No. Its processing characteristics, packaging compatibility, intended use and relevant controls must first be assessed.
Who chooses the net fill target?
The brand defines the intended user experience and product requirements. The target and practical control method should then be reviewed and approved with the filling partner.
Can sachet artwork be changed just before production?
Any change may affect printing, packaging supply, cost, schedule and compliance checks, so it should pass through the agreed revision process.
Conclusion: A clear pre-filling brief brings the product, intended use, packaging, quality expectations and delivery plan into a single decision framework. Reliable sachet filling starts with good technical preparation.