Sachets for Pharmaceuticals and Cosmetics: Material and Equipment Requirements

Two industries, one format, different rules

The pharmaceutical and cosmetics industries were the first to adopt sachets—single doses here, samples there. Both require small fill volumes, secure seams, and a clean appearance, but they have different testing requirements: Pharmaceutical manufacturers thoroughly document every batch and package products in high-barrier laminate; the cosmetics industry markets the packaging as part of the product experience and requires a perfectly aligned print image. The machine platform for both is the Packaging Machine – The differences lie in the materials, environmental technology, and documentation.

Pharmaceutical Sachets: The Fill Volume Is the Dose

A single serving of active ingredient in a sachet is not a suggested serving size, but rather the actual dose—which is why stricter tolerances and more stringent requirements apply:

• Formats: 4-sided seals measuring 60 × 80 to 80 × 120 mm; effervescent powders and ORS powders weighing 2.5 to 10 g; active ingredient granules in stick packs weighing 0.5 to 3 g.
• Dosing accuracy: ±0.5 to ±1 % with screw feeder—for powders with a fill weight of less than 1 g, every tenth of a gram counts. The page on small powder filling machine.
• Material: High-barrier laminate with an aluminum intermediate layer; moisture protection must be effective throughout the entire shelf life; industry standards typically specify permeability levels below 0.5 grams per square meter per day.
• Surroundings: Dry production environment (relative humidity below 35 % for hygroscopic powders), separate lines for related products to prevent cross-contamination.
• Documentation: Every batch is traceable; the formulation and sealing parameters are logged; and a release inspection, including a leak test, is performed on each batch.

To provide some context regarding the machine side: Equipment for this sector is ordered in a GMP-compliant configuration—stainless steel construction, CIP-capable product paths, and validatable processes. The article on Cleaning and Hygiene.

Cosmetics Sachets: Packaging Is Marketing

Cosmetic samples are a brand’s first point of contact—the texture, printing, and ease of opening all contribute to the product experience. Technically speaking, this means:

• Formats: 4-sided seals measuring 45 × 65 to 70 × 100 mm, with fill volumes ranging from 0.5 to 15 ml (creams, gels, lotions) or 0.5 to 10 g (powders, balms).
• Tempo: 40 to 80 pouches per minute for high-viscosity creams, 100 to 150 pouches per minute for low-viscosity shampoo and shower gel samples.
• Dosage: Piston dispensers for pastes (±0.5 %), peristaltic or time-based metering for surfactants—a comparison of the pump types can be found in the article on the sachet filling system.
• Material and Appearance: High-quality composites with an exterior coating and a metallic finish; for products containing active ingredients (vitamin C, retinol), an aluminum barrier to prevent oxidation.
• Printed image: Register marks must be used to control the film web—the design, logo, and seal border must align with millimeter precision; otherwise, the sample will look cheap.

A word of caution: Cosmetic samples do not require a cleanroom line—the regulatory burden under the Cosmetics Regulation lies in product safety, not in the cleanroom class. Anyone who applies pharmaceutical requirements to cosmetic samples is paying for precision that no inspector requires.

What Both Industries Have in Common

Three requirements run through both worlds:

1. Small fill volumes with tight tolerances – Dosing accuracy is the number one quality feature, because the customer doesn't weigh the portion—they simply trust it.
2. Seam Strength and Leak-Tightness – 8 to 12 N per 15 mm seam width are standard industry target values; the methods for achieving this are discussed in the article on Sealing Technology for Sachets.
3. Traceability by Batch – The film batch, formulation, sealing parameters, and release test must be documented together.

Choosing a Manufacturer: Four Questions to Ask Before Placing an Order

1. Is there a specification for the parts that come into contact with the product? SS304 stainless steel as standard; SS316 for aggressive media; surface roughnesses designed for cleanable product paths.
2. Is the machine designed to be CIP-compatible? Cleanable dosing lines without dead spaces and quick-release connections are key to minimizing cleaning time later on.
3. How are recipes and sealing parameters documented? Recipe management with logging is the foundation of batch traceability.
4. What documentation is included? Circuit diagrams, part lists, and standard part drawings are included in the scope of delivery—the article on explains their importance for operation Services from China.

For liquid and paste-like products in both industries, pump dosing is also used, as specified by the Packaging Solution for Liquids describes.

Frequently Asked Questions

Can a standard machine fill pharmaceutical sachets?

A standard sachet filling machine fills the portions mechanically; for pharmaceutical applications, a GMP-compliant design is specified—stainless steel, CIP-capable product pathways, and documented processes. The equipment specifications are defined in the requirements specification in collaboration with the manufacturer.

What are the typical fill volumes for pharmaceutical sachets?

0.5 to 10 g for powders and granules, 0.5 to 5 ml for liquid dosage forms; ORS powders are also available in quantities of up to 20 g in the larger 4-side-sealed format.

What is the difference between cosmetic sachets and food sachets?

Essentially, the visual requirements: higher-quality composites, metallic printing, and precise registration mark control. The regulatory requirements of the Cosmetics Regulation pertain to product safety, not machine technology.

Are aluminum laminates required for cosmetics?

This applies only to active ingredients susceptible to oxidation, such as vitamin C or retinol; standard surfactants and creams are also compatible with PET/PE composites. The choice of material belongs in the product’s list of requirements, not in a discussion of general principles.

Related pages: Small Powder Filling Machine | Packaging Solution for Liquids | Cleaning and Hygiene in Packaging | Sealing Technology for Sachets

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