- FSSAI & AYUSH Approved
- WHO-GMP
- ISO 9001:2015
- PAN India
- contact@3rdpartypharma.com
- +91 9990906939
Certified
Certified
Approved
Approved
Quality Assurance
Product Categories
Products
Brands
Years Experience
The most common format for powder sachets — sealed on three sides with the fourth side formed from a single fold of laminate. Cost-effective, high production speed, works well for most powder and granule fills. Standard choice unless your product specifically needs the 4-side configuration.
Sealed on all four sides — no fold line. Gives a cleaner appearance and slightly better seal integrity, particularly useful for larger sachets or products with higher moisture sensitivity. Marginally slower production speed than 3-side seal.
Long, narrow format — commonly used for single-serve protein, electrolyte mixes, and instant beverage powders. Easy to tear and pour directly into a bottle. A distinct visual format that stands out on retail shelves compared to standard flat sachets.
A variation on 4-side sealing that creates a pillow-shaped sachet — used for liquid or gel fills where a flatter format doesn't work as well. Less common than powder sachet formats but available for specific liquid nutraceutical or pharma applications.
| Laminate Structure | Best For | Why |
|---|---|---|
| PET / Foil / PE | Moisture-sensitive powders, hygroscopic ingredients, effervescent products | Aluminium foil layer gives near-total moisture and oxygen barrier — the gold standard for products that degrade on exposure |
| BOPP / PE | Standard powders with moderate moisture sensitivity | Good cost-to-protection ratio — sufficient barrier for most nutraceutical powders without foil's added cost |
| Metallised PET / PE | Products needing better barrier than BOPP but at lower cost than foil | Vacuum-metallised layer gives improved barrier properties, a middle-ground option |
| PE / PE (mono-material) | Products where recyclability is a priority | Lower barrier properties but increasingly requested for sustainability-focused brands |
Pre-printed laminate roll (with your branded artwork) is loaded onto the FFS machine. Print registration and colour accuracy are checked against your approved artwork before production starts — misregistration at this stage means rejected output later.
The flat laminate is formed into a continuous tube around a forming collar, with the vertical seal applied. This becomes the "back seam" of the sachet — the seal strength here is tested during machine setup before full production begins.
Product is dosed into the formed tube through a volumetric or gravimetric filling system, depending on the flow characteristics of your product. Fill weight is monitored continuously — for powder products, flow agents may be needed to ensure consistent, non-bridging dosing.
Heat sealing bars close the top and bottom of each sachet at controlled temperature, pressure, and dwell time. Seal parameters are validated for your specific laminate — too little heat gives a weak seal, too much can burn through thinner laminates.
Individual sachets are cut from the continuous strip. An in-line checkweigher rejects any sachet outside the acceptable fill weight range — this runs on every single unit, not a sample check, so out-of-spec sachets never reach the finished goods count.
Random samples from each production run undergo seal integrity testing (burst test, dye penetration test). Cleared sachets are counted and packed into your secondary packaging — cartons, pouches, or dispensers — and dispatched with your Certificate of Analysis.
Every sachet passes through an in-line checkweigher during production. Out-of-spec units are rejected automatically — this catches dosing problems at the individual sachet level, not just at a statistical batch sample.
We assess moisture sensitivity and shelf-life requirements before recommending a laminate structure. Getting this right at the start avoids stability failures that show up months after launch — when it's much harder and costlier to fix.
Burst and dye penetration testing isn't optional or occasional — it runs on samples from every batch. A weak seal that passes visually but fails under transport pressure is exactly what this testing catches.
Different products suit different sachet formats. We don't push every client toward whichever format is fastest to run on our machines — we recommend based on your product and market positioning.
Whether your product is a dry powder blend, a granulated formulation, or a liquid/gel fill, our FFS lines are configured to handle the full range — no need to find separate manufacturers for different fill types.
Small first-order clients and large recurring ones get the same manufacturing process, the same QC discipline, and a Certificate of Analysis with every batch.
| Test Parameter | What It Confirms |
|---|---|
| Net Fill Weight (100% In-Line Check) | Every single sachet checked — not sampled — for accurate dose delivery |
| Seal Integrity (Burst & Dye Penetration) | Sachet won't leak or fail during shipping, storage, or handling |
| Print Registration | Branded artwork prints correctly aligned — no cut-off text or misaligned graphics |
| Moisture Ingress Testing | Laminate barrier is performing as specified — critical for hygroscopic fills |
| Content Uniformity | Active ingredient consistently distributed across sachets from the same batch |
| Microbial Limits | Bioburden within acceptable limits per product category |
Ready to launch your own brand?