Powder filling co-packer: auger filling from 1 g sticks to 1.5 kg pouches.
We auger-fill dry powders into sachets, stand-up gusset pouches and zipper pouches today, and stick packs from December 2026. Every run is checkweighed or sample-weighed against a written fill target, and every pack is lot coded.
Quick answer: Powder filling at North Lakes uses an auger filler on a horizontal form-fill-seal line. We fill 5 g to 1.5 kg into sachets and pouches today and 1 g and up into stick packs from December 2026. Fill targets follow NIST Handbook 133: label +1% for 30 g and over, +2–3% for 5–30 g, +3–5% under 5 g.
What is auger filling, and why is it used for powder?
An auger filler turns a screw inside a funnel a set number of turns. Each turn moves a consistent volume of powder into the pack. It handles fine, dusty and poorly flowing powders that a cup or weigh filler can't, which is why it's the standard for protein, electrolytes, greens and drink mixes.
Augers are tuned to each powder. Bulk density, particle size and how the powder flows all change the fill. We dial in the auger on your actual product, then hold it with checkweighing.
What can you fill?
| Format | Fill range | Status |
|---|---|---|
| Sachets | 5 g and up | Running |
| Stand-up gusset pouches | up to 1.5 kg | Running |
| Zipper pouches | up to 1.5 kg | Running |
| Stick packs (20/30/40/50 mm) | 1 g and up | December 2026 |
| Hand-filled gusset bags | by job | Running, no machine minimum |
Typical products: whey and plant protein, electrolyte and hydration mixes, greens and superfood blends, collagen, creatine, pre-workout, drink mixes, sweeteners such as allulose, and seasonings. Particles up to 1/8 inch.
How accurate is powder filling?
Accurate enough to be legal on every pack, with a small planned overfill. NIST Handbook 133 requires the lot average to meet the label and limits how light any one pack can be. For packs under 36 g that limit is 10% of label.
| Label fill | Our standard target |
|---|---|
| 30 g and over | Label +1% |
| 5–30 g | Label +2–3% |
| Under 5 g | Label +3–5% |
Need tighter? We can run closer to label with 100% checkweighing or extra sampling, priced accordingly. The full explanation, with an MAV table by pack size, is in our net contents and overfill guide.
How do you check fill weights?
- Inline checkweighing where the checkweigher's accuracy fits the fill.
- Lab balance sampling for 1–5 g fills: about 10 packs every 15–30 minutes on a 0.001–0.01 g balance.
- Film tare per roll, so film weight never hides a light fill.
- Records on the batch record, available to you on request.
Scales are verified daily with certified, NIST-traceable test weights.
How much powder should I send?
Plan on about 110% of theoretical (units × label weight) on small runs, closer to 105% on large ones. That covers the small overfill that keeps every pack legal, plus process loss: start-up and calibration packs, checkweigher rejects and powder left in the hopper. Those losses are mostly fixed, so small runs lose a bigger share. For 10,000 sachets at 10 g (100 kg theoretical), send about 105–110 kg. Anything left over is yours.
How do you control dust and humidity?
Powder rooms get dusty and powders pick up moisture. We run HEPA air scrubbers around the clock, capture dust at the source with HEPA vacuums, and target under 40% relative humidity in the production zone, logged twice a day. Hygroscopic products stay closed when humidity runs high.
Frequently asked questions
What is the smallest fill weight you can do?
1 g, on 20 mm stick packs once our stick pack machine arrives in December 2026. On the pouch line today, 5 g and up.
Can you fill sticky or clumping powders?
Often, yes. Agglomerated, sticky or hygroscopic powders need testing. A $750 proof-of-concept run on your real powder and film tells us before you commit.
Do you fill capsules or tablets?
No. We fill powders into flexible packaging: sachets, pouches and stick packs.
Do you fill liquids?
No. We're a dry powder facility with no liquid or wet processing.
Related reading
- What Is Horizontal Form Fill Seal?
- Sachet vs. Stick Pack: Which Packaging Format Is Right for Your Product?
- Net Contents & Overfill: NIST Handbook 133 Guide for Brands
- What Is Yield Loss in Co-Packing?
Tell us about your run.
Pricing from $2,750 flat. FDA registered. You talk to the owner.
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