Category

Procurement Manager

Taha Rehman
In Founder / Co-Founder, Packaging Solutions, Procurement Manager

The Ultimate Guide to Supplement Co-Packing: From Powders to Pouches

Packnfresh - Supplement Co-Packing

The Ultimate Guide to Supplement Co-Packing: From Powders to Pouches

You’re a supplement brand founder. You’ve spent months, maybe years, perfecting your formulation. You have a product that delivers real results, and you’ve built a brand that customers are starting to trust.

But now you’re facing a problem that has nothing to do with your formula. It’s a logistics and cost problem.

The heavy, rigid plastic tubs you’re using are a bottleneck. They are expensive to buy, expensive to store, and astronomically expensive to ship in an e-commerce and subscription-box world. You’re competing in a crowded market where brand matters, but your “brand” is a small sticker on a generic white tub.

This is the guide for supplement founders who are ready to switch to a smarter, more profitable, and more premium packaging format. We’ll explore why flexible pouches are the future of the industry and how to find a supplement packaging manufacturers to help you make the switch.

Chapter 1: The “Tub Tax”: How Rigid Bottles Are Draining Your Margin

For decades, the rigid plastic tub or “bottle” was the default for protein, collagen, and vitamin powders. In a brick-and-mortar retail world, this made some sense. But in a modern, direct-to-consumer (DTC) model, it’s a financial drain.

We call this the “Tub Tax”—a series of hidden costs you’re paying at every step:

  • You Pay to Ship Air: Tubs are mostly empty air, and they don’t collapse. In an e-commerce world ruled by Dimensional Weight (DIM), you are paying carriers to ship that empty space.
  • You Pay to Store Air: A single pallet of empty tubs takes up a massive amount of expensive warehouse space.
  • You Pay for Inefficiency: Tubs are heavy, prone to cracking, and have high material costs compared to their lightweight counterparts.
  • You Pay with Your Brand: Your branding is limited to a small, applied label. You look like everyone else on the shelf.

This is why you see the most innovative, fastest-growing supplement brands making a universal switch.

Chapter 2: The Pouch Revolution: The #1 Format for Modern Brands

The future of supplement packaging is the flexible, small-format (< 2lb) stand-up pouch.

This isn’t just a trend; it’s a strategic move to a superior format. For a direct-to-consumer brand, pouches solve every problem that tubs create.

  • They Slash Shipping & Storage Costs: A lightweight, form-fitting pouch is the perfect e-commerce package. It’s 70%+ lighter, takes up less space in a subscription box, and drastically cuts your DIM weight shipping costs. One pallet of flat pouches holds the equivalent of 15-20 pallets of empty tubs.
  • They Are a Premium Brand Canvas: The entire pouch is your “billboard.” You get edge-to-edge, stunning, full-color printing. A pouch looks and feels premium, allowing you to stand out in a sea of generic tubs.
  • They Offer a Better Customer Experience: Pouches are portable (gym bags, travel), resealable, and create less plastic waste. This aligns perfectly with the values of a health-conscious consumer.
  • They Unlock New Markets: Pouches allow for two key formats:
    • Bulk Pouches (1-2 lb): The new standard for your core protein/collagen product.
    • Single-Serve “Stick Packs”: The ultimate tool for trial, travel, and subscription box “samplers.”

(Deep Dive: Custom Vitamin Packaging: Why Pouches Beat Bottles)

(Deep Dive: Finding a Low-MOQ Supplement Co-Packer)

Chapter 3: The Science of Supplement Packaging (Protecting Your Formula)

Your #1 asset is your formula. Your packaging’s primary job is to protect its potency and freshness from its two greatest enemies: moisture and oxygen.

This is where your co-packer’s food science expertise is non-negotiable.

1. The Moisture Menace (Clumping)

Powders (especially those with botanicals or vitamins) are hygroscopic—they love to absorb moisture from the air. This causes clumping, ruins mixability, and can degrade the product.

  • The Solution: A high-barrier pouch film is your first defense. The second is a desiccant (a moisture-absorbing packet) inserted into the pouch by your co-packer. This “pulls” all residual moisture from the pouch, keeping your powder perfectly dry.

2. The Oxygen Problem (Degradation)

Oxygen is the enemy of freshness. It oxidizes fats (going rancid) and rapidly degrades the potency of sensitive ingredients like vitamins (Vitamin C, E) and Omega-3s.

  • The Solution: An oxygen scavenger (or “absorber”). This is a small packet that we insert into the pouch, which then absorbs 99.9% of the destructive oxygen, “locking in” freshness and protecting the potency of your formula for its entire shelf life.

(Deep Dive: What is Active Packaging? A Practical Guide)

Chapter 4: The Compliance & Safety Mandate (Your ERP “Defense”)

The supplement industry is governed by strict FDA regulations (cGMP). You are legally responsible for the safety and traceability of your product, and “I don’t know” is not an answer.

This is why your co-packer’s internal software is critical.

  • DIY Risk: Trying to track ingredient lots across your supplier, your blender, and your packager via spreadsheets is a massive compliance risk.
  • The Professional Solution: A true co-packing partner, like Pack’n Fresh, runs on a single ERP (Enterprise Resource Planning) system. This provides a digital, lot-level “chain of custody” from the moment a raw ingredient arrives to the moment your finished pouch ships. In the event of an audit or recall, you have an instant, professional report.

(Deep Dive: Why Your Co-Packer’s ERP System is Your Best Defense)

Chapter 5: How to Choose Your Supplement Co-Packer

You’re ready to move to pouches. Now you must choose a partner. Be careful: the co-packer who fills 50lb bags of flour is the wrong partner for your high-value, 1lb pouch of protein.

You need a specialist. Ask these questions:

  • What is your specialization? You want to hear: “We specialize in small-format (< 2lb) pouches and turnkey co-packing.” This is our exact focus at Pack’n Fresh.
  • What is your background? You want to hear: “Our co-founders come from food science and quality control.” This proves they are experts in product safety, not just machine operators.
  • What is your equipment portfolio? You want to hear: “We have an extensive portfolio of equipment.” This is the key to flexible MOQs. It means they have the right-sized machine for your brand, whether you’re at 5,000 units or 500,000.
  • Do you offer turnkey services? The answer must be “Yes.” A partner who can source your ingredients, blend your formula, and pack your product is the only way to simplify your business and scale.

Your Next Step: From Bottleneck to Breakout Brand

Stop letting rigid tubs and high shipping costs drain your margins. The move to flexible pouches is the single most effective way to cut costs, elevate your brand, and create a better customer experience.

Pack’n Fresh is the expert turnkey supplement co packer for scaling supplement brands. We provide the food-science expertise, the state-of-the-art pouching equipment, and the ERP-backed compliance you need to compete and win.

Stop paying the “Tub Tax.” Contact us today for a consultation.

Admin User
In Packaging Solutions, Procurement Manager

Meal Kit Packaging Cost: A Breakdown of Boxes vs. Lightweight Pouches

Meal Kit Packaging Cost

The Critical Mistake in Calculating Meal Kit Packaging Cost

When meal kit founders calculate their meal kit packaging cost, they almost always make one critical mistake: they only look at the per-unit cost of the outer box. The truth is, your meal kit box isn’t your product; it’s the shipping container. The *real* cost is a complex bundle of materials, freight, labor, and even the customer’s experience.

For years, the standard corrugated box was the default. But as the market matures and margins get tighter, savvy brands are realizing that boxes are heavy, bulky, and shockingly expensive to ship. The strategic shift to lightweight, flexible pouches for the ingredients *inside* the box isn’t just a trend—it’s a critical, data-driven, cost-saving measure. Let’s break down the true cost comparison.

1. The “Dimensional Weight” Shipping Trap

Freight carriers like FedEx and UPS don’t just charge for how much your box weighs; they charge for how much space it takes up. This is called dimensional weight (DIM), and it’s the single biggest hidden fee in the meal kit packaging cost structure.

The Box Problem: You Are Paying to Ship Air

A large, half-empty box filled with smaller rigid containers (jars, tubs) and void-fill (like bubble wrap or crinkle paper) costs a fortune. That 1 oz of spice in a 4-inch-tall plastic jar, surrounded by 6 inches of air-filled pillows, might be billed as 2 lbs by the carrier. You are literally paying freight charges for empty space.

The Pouch Solution: Slashing DIM Weight

Flexible pouches are form-fitting and lightweight. They allow you to pack all your ingredients into a much smaller, denser final box. This single change can slash your DIM weight costs by 20-30% or more, which are often the most expensive part of your fulfillment budget.

2. The Hidden Labor and Material Costs

The cost of the box itself is just the beginning. The real cost is the “ecosystem” of packaging needed to fill it.

The “Packaging Avalanche” Problem

A typical meal kit box requires an entire team of other packaging: the outer box, tape, void-fill, and separate rigid containers (plastic tubs, clamshells, jars) for every single spice blend, sauce, or chopped vegetable. Your team (or co-packer) has to source, store, and manually assemble all these different pieces. This is a DIY packaging nightmare that multiplies your SKUs and labor costs.

The Pouch Solution: Consolidation

A turnkey co-packer specializing in pouches (like Pack’n Fresh) consolidates this entire, complex process. We source the high-barrier film, blend the spices, and automatically portion, pack, and seal the finished, branded ingredient. Your “packaging” for that ingredient becomes a single, pre-portioned item. This dramatically cuts down on material SKUs, storage needs, and the expensive labor time required for manual kitting.

3. The Customer Experience Cost: A Bad Unboxing

Don’t underestimate the long-term financial cost of a bad unboxing experience. It directly impacts customer loyalty and repeat purchases.

The Box Problem: Wasteful and Frustrating

Customers are growing tired of the “packaging avalanche.” They are left with a mountain of non-recyclable plastic tubs, a bulky box to break down, and plastic air pillows that fill their trash can. It’s wasteful, feels cheap, and creates a negative brand association—a significant hidden cost.

The Pouch Solution: Premium and Sustainable

High-quality, custom-printed pouches create a premium, organized, and professional experience. The customer receives a neat, easy-to-open set of ingredients that feel thoughtfully prepared. It reduces household waste, reinforces the value of your brand, and makes the customer feel good about their purchase—leading to better reviews and higher retention.

The Verdict: Where Pouches Win the Cost Battle

Boxes still have their place—as the final *shipper*. But for packaging the *actual ingredients*—especially small-format items like spices, sauces, grains, and powders—pouches are the undisputed financial winner. Analyzing the total meal kit packaging cost reveals a clear picture:

  • Lower Freight Costs: Pouches slash DIM weight, saving you money on every single order.
  • Lower Material Costs: They eliminate the need for a separate tub, jar, lid, and void-fill for each item.
  • Lower Labor Costs: Automation replaces slow, expensive manual kitting.
  • Higher Brand Value: A premium, sustainable unboxing experience leads to higher customer loyalty.

Calculate Your True Meal Kit Packaging Cost

Ready to see how much you could save by switching to a turnkey pouch packaging system? Pack’n Fresh specializes in high-quality, < 2lb pouches for meal kit companies. Contact us for a free, detailed cost analysis.

Get a Free Cost Analysis

Admin User
In Packaging Solutions, Procurement Manager

How Supplement Brands Can Win with Custom Pouch Packaging

A collection of supplements in modern custom pouch packaging

Custom pouch packaging is rapidly becoming the industry standard for supplement brands, and for good reason. As the global supplement market grows, competition is fierce. While your product’s formulation is critical, its packaging is the first thing a customer sees. For savvy brands, moving from bulky bottles to flexible, modern pouches isn’t just a trend—it’s a strategic move to cut costs, enhance brand appeal, and improve the customer experience. This guide explores why custom pouch packaging is the key to standing out and scaling your business.

Key Advantages of Custom Pouch Packaging

Brands are making the switch because the benefits are too significant to ignore. From user convenience to shelf presence, pouches deliver on multiple fronts.

Superior Convenience and Portability

Today’s consumers live on-the-go lifestyles. Bulky bottles are inconvenient to carry in a gym bag or suitcase. Custom pouch packaging solves this with single-serving sachets and travel-friendly packs, making it easy for customers to maintain their supplement routine anywhere.

Stand-Out Shelf Presence

A crowded supplement aisle is a battle for attention. Custom pouch packaging offers a larger, more vibrant canvas for branding than a bottle label. With options for full-color printing, matte or gloss finishes, and unique textures, your product can create a premium, eye-catching presence that draws customers in.

Commitment to Sustainability

Modern consumers, particularly Millennials and Gen Z, actively seek out sustainable brands. Pouches use significantly less plastic than rigid bottles and are much lighter, which reduces shipping-related carbon emissions. Offering options made from recyclable or compostable materials demonstrates your brand’s commitment to the environment, a powerful purchasing driver.

Compliance and Safety in Supplement Packaging

Supplements are regulated by the FDA, with strict GMP (Good Manufacturing Practices) requirements for traceability and labeling. This is non-negotiable. Mistakes can lead to costly recalls or business closure. A professional copacker using an ERP system is vital for ensuring your custom pouch packaging meets all standards. They provide:

  • Digital lot tracking for every single ingredient and finished product.
  • Audit-ready records for FDA or GMP inspections.
  • Precise, automated portioning to ensure label accuracy.

Bottles vs. Pouches: The Financial Benefits

For small and medium-sized brands, every dollar counts. This is where custom pouch packaging truly shines, offering clear economic advantages over traditional bottles.

Lower Shipping and Storage Costs

Pouches are lightweight and pack flat, drastically cutting freight costs compared to heavy, space-consuming bottles. This efficiency extends to warehousing, as you can store more units in less space, lowering overhead.

Feasible Minimum Order Quantities (MOQs)

Testing a new product line with bottles often requires a massive upfront investment in inventory. The flexible printing process for pouches allows for smaller, more manageable print runs, reducing the financial risk of launching new SKUs and allowing you to test the market effectively.

How Custom Pouch Packaging Drives Business Growth

Good packaging does more than just hold your product; it actively helps grow your business by creating new opportunities and strengthening customer relationships.

  • Supports Subscription Models: Pre-portioned 30-day supplies in refill pouches are perfect for subscription boxes, simplifying logistics and encouraging recurring revenue.
  • Differentiates Your Brand: High-quality, thoughtfully designed custom pouches signal a premium product inside, justifying a higher price point and building brand equity.
  • Encourages Product Trials: Offering smaller, sample-sized pouches is a low-cost, low-commitment way for new customers to try your product, reducing the barrier to a first-time purchase.

FAQ: Your Custom Pouch Packaging Questions

Are pouches FDA-approved for supplements?
FDA regulates the packaging environment and labeling, not the pouch format itself. With ERP-backed copacking, you’re audit-ready.
How does pouch packaging affect shelf life?
Modern pouches use high-barrier films that protect against moisture, oxygen, and UV light just as effectively as bottles. Because they are flexible, they often contain less “headspace” (trapped air), which can actually improve the stability of powders and capsules.

Final Word

For any modern supplement brand, packaging is a critical pillar of your strategy. Custom pouch packaging delivers on all fronts: it cuts costs, ensures compliance, elevates your brand, and meets the demands of today’s consumer. It’s the smarter, more flexible solution for a competitive market.

Ready to get started? Request a free quote for your custom supplement pouches today!

Taha Rehman
In Procurement Manager

Easy Holiday Meal Kits: Pre-Cooked Thanksgiving & Christmas Dinner Solutions

Holiday Meal Kits

Stress-Free Holiday Meal Kits: Pre-Cooked Thanksgiving & Christmas Dinner Kits

How meal Holiday Meal Kits companies can become their customers’ best friend for the holidays

While the holidays can be a merry time, full of celebration and moments that turn into memories, this Precooked Thanksgiving Dinner time of year can also be accompanied by a lot of stress.

Between navigating the crowded stores, getting the house clean and cozy, and prepping feasts for days on end — it can be a lot to handle!

This is where you can come in. You can be the assistant that every parent and host has ever hoped for. You could be the manifestation of Christmas Dinner Kits Santa Clause at meal time. 

It is an increasing trend today that specialization is an attractive concept to consumers. They want to feel, no matter how big or small the company is, that their needs are known and that the company cares about meeting those needs. 

During the holidays, people make wish lists. This wish list will inspire what others give them during this season. 

How does this affect you? Request a wish list from your consumers. 

Allow for your customers to tell you exactly what they need and want during the easy holiday cooking and when they need it, This will allow you to tailor your solution to meet their needs.

For example, if there is a week in which the in-laws are coming into town or the kids are home from college, allow them to change the quantity of plates in advance. 

This should be able to happen with ease, keeping with the theme of taking stress away from the customers’ lives. 

Pack’n Fresh can even help you perfect your serving sizes which helps families with how much food they need when the seats at the table increase

A key part of the holidays is remembering and remaking the meals you grew up eating as a child. 

While you may not be able to emulate grandma, allowing your consumers to pick the dishes that remind them of memories past, will be an easy way to make the holidays feel like the holidays. 

These wonderful recipes often call for ingredients that aren’t found in the pantry the rest of the year. This makes having a supplier with a large variety a necessity this time of year. 

This is beneficial for you too because you have the ability to increase your sales, at premium even, if you so choose. 

Additionally, your product will be consumed by more people, those who possibly don’t use your services. What is better than a family endorsement and getting to try the food for a prospective client? Nothing!

That’s marketing that can’t be bought. 

While Santa Clause only comes by one night a year, you are the little elves that make your consumers’ life easier year round. This holiday season, providing a little extra help will be a great way to build brand loyalty with your consumers.