Production specs,
all in one place.
Check your product against our capabilities. If everything fits, request a quote →
| Specification | Detail |
|---|---|
| Machine type | Horizontal form fill seal (HFFS) |
| Product type | Dry powders — supplements, drink mixes, food powders, nutritional blends |
| Sachet fill weight | 9g minimum — 90g maximum (varies by powder density) |
| Gusset pouch fill weight | Up to 500g (limited by pouch width) |
| Minimum run size | 2,000 pouches per shift |
| Maximum run size | 15,000 pouches/shift (sweet spot) — single-flavor runs up to 24,000 available |
| Sachet size — minimum | 3" wide × 3" tall (roll stock) |
| Sachet size — maximum | 5.5" wide × 9" tall (roll stock) |
| Zipper pouch — maximum | 5.5" wide × 9" tall |
| Pouch formats available | Roll stock sachets, zipper pouches |
| Facility registration | FDA Registered |
| Pricing model | Day rate — starting at $3,500 per production day |
| Service area | Nationwide — contiguous United States |
| Not available | Liquid fills, semi-solid fills, tablet or capsule packaging, allergen cleanout runs (multi-flavor requires same film size, no allergen separation needed) |
| Multi-flavor runs | Yes — multiple flavors in a single day if film size matches and no allergen cleanout required |
Two formats.
Every powder between.
We run sachets and zipper pouches in a wide range of sizes. Here's what each can do.
Roll Stock Sachets
Single-serve & multi-serve formats
Zipper Pouches
Resealable, retail-ready format
HFFS — built
for powder.
Overgang operates a horizontal form fill seal (HFFS) machine — the industry standard for high-precision powder dosing in sachets and flexible pouches. Unlike vertical machines, horizontal form fill seal is particularly well-suited to free-flowing powders and products that need tight weight control at lower fill weights (as low as 9 grams for sachets, up to 500g for gusset pouches).
The machine forms the pouch from roll stock material, doses your powder via auger fill, seals the package, and cuts it to size — all in a single continuous pass. This is what delivers consistent fill weights and clean seals across your entire run, whether you're running 2,000 or 15,000 pouches.
You supply the bulk powder and the roll stock. We handle machine setup, calibration, fill weight verification, and quality checks throughout the run.
What we need
from you to run.
We handle everything on the production floor. Here's what you need to have ready before your run date.
Your bulk powder
Ship us your bulk powder, pre-blended and ready to fill. We do not offer blending or formulation services — your product arrives ready for the machine.
Your roll stock material
You supply the printed or unprinted roll stock film for your sachets or zipper pouches. We'll confirm compatibility before your run date.
Confirmed specifications
Pouch size, fill weight, and target quantity confirmed before your production date is scheduled. We'll walk through these on your quote.
Finished pouches.
What happens next.
Bulk Packout
Your finished pouches are counted, bagged in bulk, and shipped to you or your fulfillment center. This is what we recommend for small businesses and anyone still proving their concept. It's faster, cheaper, and gives you flexibility in how you package for different channels. Don't pay for assembly until you know exactly what you're selling into.
Assembly Services
Need your individual pouches placed into retail boxes or bags? We offer assembly as an add-on service for brands that need shelf-ready or DTC-ready finished cases. This is ideal once you have a proven, consistent SKU going into a defined retail or subscription channel. Assembly is priced separately — ask us about it on your quote.
Also: We can connect you with local corrugated suppliers for boxes, shippers, and retail packaging. We're not just a machine — we're a resource. Think of us as a consultant invested in helping your small business grow, not a vendor trying to upsell you at every turn.
Need more than
15,000? We can do that.
15,000 pouches per shift is where our customers typically land. But it's not our ceiling.
When you need overflow capacity or a larger single-flavor run, Overgang can push up to 24,000 pouches in a production day. That's not a number most small-batch co-packers will give you, because most don't have the throughput.
Even better: if you're running multiple flavors of the same product and your film size is consistent across SKUs, we can run them back-to-back in the same day — with no allergen cleanout required between runs. That kind of operational flexibility is virtually unheard of in the co-packing space. Most facilities require full cleanouts between every flavor change. We don't.
Why this matters for youRunning multiple flavors in a single day means you're paying one day rate — not one day per SKU. For brands with 3–5 flavors, that's a significant cost difference. And the 24,000-unit ceiling means Overgang can grow with you as your volumes scale.
Want to own the
machine without
running it?
Most brands at a certain volume start thinking about bringing production in-house. The problem: equipment is expensive, operators are expensive, and running a machine is a full-time operation that has nothing to do with building your brand.
Overgang offers fractional ownership of our horizontal form fill seal machine — modeled on the same logic as NetJets. You get the operational reality of owning dedicated production capacity without the overhead of owning the building, hiring the team, or managing the floor. We provide the labor, the equipment, and the expertise. You provide the product and commit to a set number of production days per year.
Commitments range from 6 to 30 production days per year.
Your product
Bulk powder, pre-blended and ready to fill. Roll stock film with your branding. Your SKUs, your formulas, your brand.
Everything else
The machine. The operators. The facility. The FDA registration. Setup, calibration, quality checks, and finished goods output.
6–30 production days per year
Your fractional ownership means guaranteed capacity on your schedule. No competing for run slots with other customers. Your days are yours.
Dedicated capacity without the overhead
All the benefits of owning production equipment — cost control, scheduling priority, operational visibility — with none of the liability, staffing, or maintenance headaches.
Specific questions,
answered directly.
If your question isn't here, reach out through our quote form.
Can Overgang fill both sachets and zipper pouches in the same run?
No — each production day is set up for a single format and fill weight. If you need both formats, those would be two separate production days.
What powder types can Overgang run?
We run any free-flowing dry powder — protein powders, pre-workout blends, electrolyte mixes, collagen peptides, greens powders, drink mixes, and similar food or supplement formats. If your powder has unusual flow characteristics (very fine, clumping, hygroscopic), let us know upfront and we'll assess compatibility.
Does Overgang supply the roll stock packaging material?
No — you supply your own printed or unprinted roll stock. This keeps your artwork and material choices entirely in your control. We'll confirm your roll stock is compatible with our machine when we review your specs.
Can Overgang run liquid or semi-liquid products?
No. Our equipment is purpose-built for dry powder fills only. We cannot run liquids, gels, pastes, or semi-solid products.
What is the maximum pouch size Overgang can run?
For both sachets and zipper pouches, our maximum is 5.5 inches wide by 9 inches tall. Our minimum sachet size is 3 inches by 3 inches.
Does Overgang do blending or formulation?
No — we are a filling and packaging operation. Your product arrives pre-blended and ready to fill. We do not offer ingredient sourcing, formulation, or blending services.