Small pouches
filling service
Contract filling of liquids, creams, pastes or powders in small pouches. We review the product, quantity, film and format for your B2B project.
Applications
Which applications are sachets suitable for?
Product samples
Small portion pouches as first or product samples, neutral or printed, ideal for mailings, trade fairs or inserts.
Powder & granulate pouches
Filling of powders and granulates into sachets - for industry, cosmetics, food supplements and technical products.
Technical enclosed items
Talcum, desiccants, additives and assembly aids as cleanly packaged enclosed items for technical products.
Cosmetics & fragrance
Cosmetic powders, bath salts, fragrance sachets and care products in sample or retail format.
Cleaning additives
Portioned cleaning powders, detergent additives and chemical additives as dosing pouches.
Industrial products
Special projects and B2B applications for granulates, desiccants and other technical bulk goods.
Inquiry information
What we need for a quote
So that we can evaluate your inquiry quickly and realistically, please send us the following information. The more complete the details, the faster you receive a reliable quote.
Sachet inquiry
Related services
More from this area Powders & sachets
All specialized filling services for powders and granulates - directly from our facility in Roßtal.
Sachets & Powders Overview
The complete overview of all powder and sachet services at our Roßtal facility.
07.01
Talcum filling service
Pack the finest powders with low dust - cleanroom environment also possible.
07.03
Technical Powders
Industrial and specialty powders - from metal oxides to polymers, ATEX-compliant.
07.04
Powders filling DE
Made in Germany - ISO 9001, HACCP & GMP. Produced entirely at the Roßtal facility.
Fill products
What Avoria GmbH fills into small pouches - all consistency classes
Liquids
Aqueous solutions, oil-based liquids, low-viscosity serums. Fill quantities 5-50 ml. Cosmetic tonics, essential oil blends, liquid food supplements, disinfectants.
Creams & gels
Medium- to high-viscosity products. Hand creams, face creams, aloe vera gels, lubricating gels, topical preparations. Fill quantities 2-30 g. Piston configuration depends on viscosity.
Pastes
Highly viscous, cohesive products - toothpaste, heavy body butters, food pastes. These require specific piston heads and controlled line speed for correct dosing.
Powders & granulates
Free-flowing and cohesive dry materials - supplement powders, talcum, cosmetic active powders, food ingredients. Auger dosing - a different technology than for liquids.
Decided before the test run: The dosing technology depends on the consistency. We review the product data sheet, viscosity measurements or the powder's flow behavior before setting the production date.
Dosing technology
Piston dosing or auger dosing - which method for which product
Piston dosing
Liquids · creams · pastes
A piston-cylinder unit draws in a defined product volume on the suction stroke and dispenses it precisely into the pouch film. The fill volume is determined by the piston stroke - not by the product's flow behavior. Calibrated for fill quantities from 2 ml to 100 ml, from thin serums to viscous pastes.
Auger dosing
Powders · granulates
A rotating auger moves a defined amount of powder into the filling funnel per revolution. The fill weight depends on auger pitch, speed and bulk density - not on gravity flow. The right method for cohesive powders that would bridge, and for free-flowing powders that would overdose under gravity.
Pouch formats
Small pouch formats - three-side-seal, four-side-seal, stick pack
Three-side-seal pouch
Two film layers, three sides sealed, the fourth side closed after filling. The most common format for cosmetics and food samples. Up to approx. 100 ml/g. Broad format flexibility.
Four-side-seal pouch
All four edges sealed. A symmetrical appearance for thicker or more dimensionally stable contents. Higher seal integrity for viscous fill products. Slightly more film material.
Flow-wrap / pillow pouches
Formed from a single film roll, sealed lengthwise and at both ends. Higher production speed, lower material costs. Common in food applications.
Stick pack
A long, slim format - typically 15-25 mm wide, 60-120 mm high. Standard for food supplements, instant drinks and single-dose applications. For powders and liquids.
Quality assurance
From incoming raw material inspection to the sealed small pouch
Every production order begins before the dosing line starts. Raw materials or finished product deliveries are checked against the supplier CoA - identity and basic quality parameters verified before the batch enters production.
In production, the dosing line is calibrated to the target fill weight. A check-weighing step monitors the fill weight continuously - not just at the start and end of the run. Seal seam integrity is tested at defined intervals.
"An undocumented deviation is not a cost saving - it is a liability." This principle is anchored in our quality system.
In-house laboratory capacity means: identity verification internally - no shipping to an external lab with waiting times. For products where incoming inspection is critical, in-house testing shortens the goods-receipt hold time.
Batch record
Documented for every production order
- →Line speed and dosing settings
- →Check-weighing results
- →Heat-sealing temperature and pressure (documented parameters)
- →Operator releases and production date
- →Batch number and raw material batch tracking
- →Certificate of Analysis (CoA)
Certification
ISO 9001 and HACCP in small pouch filling
ISO 9001:2015
Externally certified. Documented procedures, defined control points, calibrated equipment. For supplier qualification: reduces the documentation effort on the client side considerably.
HACCP & EU Cosmetics Regulation
HACCP for food contact and food ingredient applications. For cosmetic pouches: ISO 9001 as structural evidence for the GMP requirements of EU Cosmetics Regulation 1223/2009/EC.
Supplier qualification
Process documentation, batch records, corrective actions - in place within Avoria GmbH's quality system and available for audits. On-site audit visits are possible.
Direct manufacturer Roßtal
Produktion in eigenen Strukturen in Roßtal, Bayern, bei Bedarf ergänzt durch spezialisierte Partner aus unserem geprüften Netzwerk. Die Charge, die Sie beauftragen, wird dokumentiert und rückverfolgbar produziert. Testlauf vor Serienproduktion Standard.
Not within our scope: Products requiring an AMG manufacturing license, controlled substances (BtMG) and substances requiring pharmaceutical cleanroom production. This is communicated at the first inquiry.
Important note
Not every product can be filled without assessment
Flow properties, film suitability and sealability must be checked before production starts. We carry out this assessment transparently - you receive clear feedback on feasibility and conditions.
For a quick assessment we need
- →Product designation and product type (powder, cream, liquid)
- →Fill quantity per sachet (grams or ml)
- →Total quantity (units or kg)
- →Desired pouch format (stick pack, pillow, flat pouch)
- →Film material: from us or supplied by you?
- →Printing desired? If so, are print files available?
- →Raw material: from us or supplied by you?
- →Desired delivery date
Why us
Why Contract Filling Germany
- Over 15 years of experience in sachet filling
- B2B only - no end consumers
- Customer-supplied raw materials and packaging materials possible
- Feasibility check before every order
- Series production and contract filling in our own facilities - ISO 9001 and HACCP compliant
- Cartoning and shipping preparation possible in our own facilities
Process
From inquiry to finished delivery
Submit an inquiry
Send product type, fill weight, quantity, film and printing preference.
Technical assessment
We check format, film, dosing and economic feasibility.
Quote
A clear, calculated quote incl. production plan and delivery date.
Sample production
On request, first samples for release before series start.
Series production
Filling, cartoning, documentation and shipping preparation in our own facilities, supplemented where needed by specialized partners from our network.
Enquire about a small-pouch project
Your contact details and a short project description are enough to get started. Add technical details if already known.
FAQ
Frequently asked questions
Frequently asked questions about sachet filling - answered quickly.
Sometimes a short call is faster than any form.
Call now →Minimum order quantities depend on product type and format. For most small pouch products, MOQs start at 500 units for prototype and test runs and from 2,000-5,000 units for series production. For exact figures based on your product, contact us directly.
From confirmed test run to series delivery it is typically 10-14 working days once all materials and packaging films are in place. From first inquiry to a confirmed production slot, most standard projects take 2-5 working days after complete product documentation.
Yes. Product development is available as an integrated service - Avoria GmbH can support formulation, stability testing and regulatory documentation alongside contract filling. Particularly relevant for brands developing a new product and looking for a single manufacturing partner from formula to finished sachet.
Yes. Test runs are standard before series production. A test run confirms fill weight tolerance, seal seam integrity and production parameters, and produces a batch record. It also lets the client evaluate the finished pouch before ordering a full production batch.
Avoria GmbH ist Direkthersteller und produziert Kleinbeutel in eigenen Strukturen am Standort Roßtal, Bayern. Spezialisierte Partner aus unserem geprüften Netzwerk werden bei Bedarf transparent eingebunden. Jede Kleinbeutel-Charge wird dokumentiert und rückverfolgbar produziert und versandt.
Liquids, creams and pastes are filled with piston dosing - a piston-cylinder unit doses the fill volume precisely, regardless of viscosity. Powders and granulates are filled with auger dosing - the fill weight depends on auger pitch, speed and bulk density, not on flow behavior.
Yes. HACCP certification covers food contact and food ingredient applications. ISO 9001:2015 certification applies to the entire production including cosmetic small pouch filling - in line with the GMP requirements of EU Cosmetics Regulation 1223/2009/EC. Both certifications are maintained externally.
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