Custom Printed Supplement Pouches for Capsules, Gummies and Powders

What is a supplement pouch and why swap from a tub?

A supplement pouch is a flexible film pack that takes the place of a plastic tub or glass bottle. The blue sachet in the photo holds one dose behind a tear notch. The stand up pouch beside it adds a gusset, a zipper and a window.

Tubs are mostly air. A 60-capsule tub ships at three times the volume of a pouch holding the same capsules, so postage and shelf space both drop.

A pouch also seals tighter than a screw cap. Once the zipper is pressed, the capsules sit in a near-closed foil envelope rather than a half-empty tub.

Which supplement products go into pouches?

Any dry supplement works. Liquids and oils go into a spout format instead. The list below covers what UK brands send us most often.

Powders with a scoop usually need the larger sizes on our pouches for protein and sports powders page, where the scoop sits on top of the fill.

• Capsules and softgels, 30 to 120 per pouch
• Gummies for vitamins, sleep and hair, 30 to 60 pieces
• Collagen, creatine and greens powders from 250 g
• Electrolyte and pre-workout sachets of 5 to 20 g
• Herbal teas and loose botanical blends
• Chewable tablets and lozenges

How many capsules fit in a supplement pouch?

Capsule size sets the pouch size. A size 0 capsule is about 21 mm long and 60 of them need roughly 150 ml of space. Softgels are rounder and pack tighter.

Gummies need more room than their weight suggests. They should not be squeezed, or they stick into a block in warm post.

Which laminate protects the active ingredients?

Three things damage supplements in storage: moisture, oxygen and light. Capsules soften and stick when they take on water. Fish oil softgels go rancid with oxygen. Vitamin C and probiotics lose potency in light.

A PET / foil / PE laminate blocks all three. Metallised PET / PE is a lighter choice for short shelf lives. Clear PET / PE shows gummies but lets light in, so pair it with a short date.

Food-contact, high-barrier and compostable film options are available on request and confirmed on your quote. Read how each layer works in our plain guide to barrier films.

Zippers, tear notches and windows on supplement pouches

Monthly packs take a press-to-close zipper. Pick a slider zipper if your customers are older or open the pouch with wet hands at the sink.

Single-dose sachets take a tear notch and nothing else. Put the notch on the short side so the powder pours into a glass rather than across the worktop.

A window sells gummies, because people want to see the shape and colour. Keep windows off capsule pouches with light-sensitive actives. Our foil bags with a clear window page shows the window options.

A hang hole suits gym counters and health shops. Ask for it above the top seal.

Printing a supplement label on a pouch

Regulated panels take most of the back: the ingredient list, nutrition information, dose directions, allergens, batch and best before. Plan these panels first and fit the front artwork around them.

A matte or soft touch finish reads as premium in this category. Metallic effect ink picks out a brand mark on dark foil. White under-print keeps colours bright on metallised film.

Send what you have and our designers lay out the panels free and send a proof. The artwork guide for printed pouches lists sizes and bleed.

How do you fill supplement pouches on a small line?

Most UK supplement start-ups fill by hand or with a tabletop capsule counter. This sequence keeps dust out of the seal and the counts right.

1. Dry the room and keep powders covered; moisture in the air lands on the inside of the pouch.
2. Count capsules with a tray or tabletop counter straight into the open pouch.
3. For powders, use a funnel that reaches below the seal line and fill by weight.
4. Tap the pouch so nothing clings to the inside above the fill.
5. Press the zipper shut, then heat seal above it with the jaws set for the laminate.
6. Add the batch code and date on the panel you left for it.

Sachet machines and film rolls

Once a brand passes a few thousand sachets a month, hand filling stops making sense. A vertical form fill seal machine makes the sachet from a reel of printed film, fills it and seals it in one pass.

The same artwork runs on the reel, with eye marks printed at the edge so the machine cuts each sachet in register.

Our printed film rolls for sachet machines page covers reel widths and repeat lengths. Tell us the machine model and we set the reel to it.

Mistakes that cost supplement brands money

Ordering a clear pouch for a product that lists light sensitivity on its own data sheet is the first. The product looks lovely and loses potency on the shelf.

The second is a pouch sized to the capsule weight rather than its volume. Sixty capsules weigh 40 g and take 150 ml. Order on volume.

The third is skipping the zipper on a 90 count pack to save a few pence. Customers decant into an old tub and your pouch never reaches the bathroom shelf.

The fourth is a batch code panel printed in a dark colour with no space for a thermal label. Leave a white box for it.

Can supplement pouches replace a carton for subscriptions?

Many do. A 30-count flat pouch slips into a padded envelope and posts as a large letter. The front carries the brand and the back carries the panels, so no carton is needed.

Brands that want a gift feel keep a carton for the first order and send refills in the pouch alone. The pouch artwork should still stand on its own.

Daily sachets can be collated into a plain outer bag with a window. See our resealable zipper pouches for refills for the outer bag.

How to order supplement pouches

Email or WhatsApp us the capsule count or fill weight, the format, the quantity and your artwork files. Quantities are quoted per order and prices start from £0.25 per unit, confirmed on the written quote.

A free design proof comes first. Production takes 4–6 business days after approval and free tracked delivery to any UK address follows in 2–3 business days.

Misprints or damage reported within 10 days with photos are reprinted or refunded. Use the supplement pouch quote request form to start.