Sachet and pouch packaging: stand-up, gusset and zipper pouches on our HFFS line.
We form, fill and seal sachets, stand-up gusset pouches and zipper pouches from your roll stock on an HMC Pouchmaster horizontal form-fill-seal (HFFS) line. Fills run from 5 g to 1.5 kg.
Quick answer: North Lakes Copacking runs sachets, stand-up gusset pouches and zipper pouches on an HMC Pouchmaster horizontal form-fill-seal line, filling powders from 5 g to 1.5 kg. Sachets are $2,750 flat up to 5,000, then $0.25 each to 25,000 and $0.18 each to 50,000. HFFS zipper and stand-up gusset pouches are quoted per job.
What is a horizontal form-fill-seal (HFFS) machine?
An HFFS machine unwinds flat printed film, folds and seals it into pouches, fills each pouch and seals the top, all in one line. Because it forms pouches from roll stock, film costs far less per unit than buying pre-made pouches. Our line is an HMC Pouchmaster. The longer version is in what is HFFS?
Which pouch styles can you run?
| Style | Good for | Pricing |
|---|---|---|
| HFFS sachet (flat pouch) | Single serves, samples, retail boxes | $2,750 flat up to 5,000; then $0.25 each to 25,000, $0.18 each to 50,000 |
| HFFS stand-up gusset pouch | Multi-serve retail, shelf presence | Quote only |
| HFFS zipper pouch | Resealable multi-serve bags | Quote only |
| Hand-filled bag or pouch | Small batches, no machine minimum | From $1.00 per pouch + $250 setup |
Not sure which? Compare them in sachet vs. zipper vs. gusset.
What film do I need?
Printed roll stock that meets our line's requirements: core size, maximum roll diameter, wind direction, web width, print repeat and eye mark. Send our roll stock film specification (PDF) to your film supplier and have them confirm each item on their quote.
Film is where most first runs go wrong. Read packaging film mistakes brands make and the $8,000 film mistake before you print.
How are pouches coded and checked?
- Every pack is lot and date coded on a Markem-Imaje SmartDate X40 thermal transfer coder.
- Fill weights are checkweighed or sample-weighed and recorded against our fill-weight policy.
- Seals are checked through the run. See seal integrity.
Frequently asked questions
Can you fill pre-made pouches?
Our machine line forms pouches from roll stock. Pre-made bags can be hand-filled for small batches; tell us on the quote form.
What is the largest pouch you can fill?
Up to 1.5 kg of powder, depending on bulk density and pouch size.
How many flavors can you run in a day?
Usually 2–3, depending on clean-out between them.
What does a changeover cost?
$250 for a flavor switch at the same pouch size with no allergen. $795 for a full clean-out, which covers a pouch size change or an allergen.
Related reading
- What Is Horizontal Form Fill Seal?
- Sachet vs. Zipper Pouch vs. Gusset Bag
- The Packaging Film Mistakes That Burn First-Time Brands
- Seal Integrity 101: What to Check, What Goes Wrong, and Why Film Sizing Takes Longer Than You Think
Tell us about your run.
Pricing from $2,750 flat. FDA registered. You talk to the owner.
Get a Quote →