What we do.
What we don't.
We are a co-packing and fulfillment operation — not a turnkey supplier. Here's the clear line between what Overgang handles and what stays with you.
What we handle
- Weight and tumble blending — we blend your formula per your spec sheet. You provide total pounds and percentage formulations. No need to arrive pre-blended.
- Horizontal form fill seal production — filling, sealing, cutting to spec
- Fill weight verification and quality checks throughout your run
- Lot numbers and batch records — you specify the format and expiration date
- Bulk packout in master cases — included in all runs
- Assembly — pouches into retail boxes or bags, priced as add-on ($0.75–$1.75/unit)
- Ecommerce fulfillment — pick, pack, ship at actual carrier cost, no markup
- Supplier connections — film, corrugated, ingredients, testing labs — we know who's good
- Shipping excess raw materials back to you — we don't hold your product hostage
- Honest advice — on sizing, packaging format, packout strategy, and when to scale
What stays with you
- Your formula — your secret sauce, always. We don't touch it, share it, or advise on it.
- Roll stock film — you source it. We can connect you with suppliers we trust.
- Raw ingredients — ship us your bulk ingredients and we blend them here. Or arrive pre-blended if you prefer. Either way, the formula and supplier relationship is yours.
- Corrugated / retail packaging — boxes, gusset bags, caddies. We'll connect you with Twin Cities vendors.
- Label design and FDA label compliance — fully your responsibility. We do not advise on this.
- Moisture and contaminate testing — on you. We can connect you with testing labs at no markup.
- Certificates of Analysis (COAs) — must be on-site at Overgang before we run anything. No exceptions.
- Spec sheet and blending instructions — total pounds, percentage formulations, all provided by you before your run date.
- Allergen declaration — required before production. Non-negotiable.
- Signed MSA — Master Service Agreement required before any production run.
Every step.
No surprises.
Here is exactly what happens from the moment you have a product idea to the moment your finished pouches ship. Who does what, when, and what to watch out for.
Dial in your product — that's your secret sauce.
Get your formula right before you talk to anyone. Perfect it in your kitchen, your lab, with your formulator — wherever. Your formula is yours and it stays yours. We don't advise on formulation, we don't modify it, and we don't share it. Once you have it dialed in, get in touch.
Size out your sachet or pouch — don't skip this step.
Bring us your fill weight, your powder density, and your target pouch dimensions. We will help you confirm the correct sizing. In some cases a small test run is required to confirm — this is always preferred over discovering bad seals after a full run because your product was sized into a sachet that's too small.
A bad seal caused by under-sizing is not a machine problem. It is a spec problem. Getting this right before you order film saves you thousands.
Order your film — and get the die lines right.
Once sizing is confirmed, you order your roll stock film from your film supplier. You will need die lines from the film company — these are the templates your designer uses to create artwork that fits the actual pouch dimensions. We can recommend film suppliers we know and trust.
Once artwork is approved by your film supplier, you're looking at 10–12 business days until your film is printed and shipped. Build this into your timeline. It is the most common scheduling bottleneck we see.
Order caddies and retail packaging — or don't yet.
If you need retail-ready packaging — gusset bags, 10/20/30-count boxes — you'll need die lines for those too. Same process: die lines to designer, artwork to supplier, lead time to ship.
For first runs: consider stickered clear bags instead of printed gusset pouches. A clear poly bag with a label is dramatically cheaper to change than a run of 15,000 printed gusset bags when your concept isn't proven yet. When in doubt, go without. Don't spend money on things you don't need to — not yet.
Order your ingredients — and own that relationship.
Overgang can point you in the right direction for ingredient sourcing, but our strong belief is that you should own the relationship with your food supplier directly. If this thing scales to a million units a month, you want that supplier relationship to be yours — not routed through a co-packer who might not always be in the picture.
Order at the right time. Ingredients have lead times too. Your film supplier, your ingredient supplier, and your production date all need to align.
Order at 110% — yield loss is real.
On a small production run, plan for approximately 10% yield loss. On larger scale runs that number drops to around 5%. This is the nature of powder filling — some product ends up in the machine, in the fill system, in the transition. It is not a defect. It is physics.
Order your ingredients and film at 110% of your expected finished output. If your loss is lower than expected — great, you have excess. If you order exact and hit 10% loss, you are short on finished goods with no way to make it up without a second run.
Sign the MSA and submit your spec sheet.
Before any production run, Overgang requires a signed Master Service Agreement. We also require your spec sheet — total pounds to be blended, percentage formulations for each ingredient, and your allergen declaration.
Lot number format and expiration date convention need to be specified by you — we apply them, but we follow your format and your dates.
We weight and tumble blend everything to your spec.
Your ingredients arrive. COAs are verified on-site. We weight and tumble blend to your exact formulation — every ingredient measured against your spec sheet, verified to your percentage formulations. Tumble blending ensures a homogenous mix before anything goes into the machine. You do not need to pre-blend — that is on us.
We follow NIST standards for weights and measures. Your product is blended accurately, documented, and ready for production.
Production run — machine does its thing.
Your blended powder goes into the horizontal form fill seal machine. Your roll stock film feeds through. The machine forms the pouch, doses the powder, seals, and cuts. We verify fill weights at the start of the run and throughout. Quality checks happen continuously.
A few minutes after startup, your product is rolling off the line. Light fills at up to 25,000 pouches per day. Medium fills at 15,000. Heavy fills around 10,000. We'll have given you a realistic estimate before your run date.
Packout — bulk or assembled, your call.
Bulk packout (standard, included): Finished pouches are counted, packed into master cases, and palletized. Shipped via pallet for larger runs, or via UPS directly to you on smaller runs. This is what we recommend for most brands — especially anyone still proving their concept.
Assembly (add-on, $0.75–$1.75/unit): Pouches placed into retail boxes, gusset bags, or subscription kits per your spec, then palletized and shipped to your fulfillment partner. Available for brands with proven, consistent SKUs going into defined channels.
Testing — if you want it, do it.
We do not do moisture testing or contaminate testing — that is on you and your team. We do not mark up testing fees. We can connect you with labs that can test anything you need — third-party, independent, accredited. You deal with them directly at their actual cost.
You sell. You save money. You scale smart.
Your finished, filled, sealed pouches are in your hands. You proved your concept on a run you could afford. You didn't tie up six figures in inventory before you knew if the product would move. You have data — sell-through rate, customer feedback, channel performance — that tells you exactly what your next run should look like.
That's the model. Scale it. Prove it. Move it. In that order.
The true cost of
ordering too much.
Nobody in the co-packing industry shows you this math. We're going to — because we've lived it and it almost broke one of our founders.
The pitch from a large co-packer sounds great: run 50,000 units, get a lower tolling cost per unit, save money. And the per-unit math is real. At 50,000 units, your tolling cost might be $0.45/unit. At Overgang for 5,000 units, it's around $0.70/unit. You save $0.25 per sachet.
What they don't show you is everything else. The ingredients for 50,000 units. The film. The corrugated. The freight. The warehouse storage while product sits. The interest on the capital you borrowed to fund it all. The carrying cost of inventory that's not moving.
And that's the optimistic scenario — where everything goes right. What happens if your formula needs a tweak after you've run 50,000 units? What if the channel doesn't convert the way you expected? What if a competitor launches the same week? What if you want a different flavor, a different size, a different format?
At 5,000 units, a pivot costs you one production day. At 50,000 units, a pivot costs you everything in that table below — plus the psychological weight of sitting on inventory you can't sell while your business bleeds cash.
The real question.
Would you rather spend $48,700 on inventory you might not sell — or spend it on paid ads, influencer partnerships, retail slotting fees, and marketing that actually proves whether you have a business?
The brands that survive their first two years are the ones that optimize for total cost of learning, not per-unit cost of production.
Small runs are expensive per unit. They are extremely cheap ways to find out if your product and channel work before you bet real money on them.
True cost comparison — 5,000 vs 50,000 units at $0.60 ingredient cost
| Cost Item | 5,000 units (Overgang) | 50,000 units (Mega packer) |
|---|---|---|
| Ingredients | $3,000 | $30,000 |
| Tolling / co-packing | $3,500 (day rate) | $22,500 |
| Roll stock film | $300 | $3,000 |
| Corrugated / master cases | $150 | $1,500 |
| Inbound freight (to co-packer) | $200 | $800 |
| Outbound freight (to warehouse) | $250 | $1,200 |
| Warehouse storage (6 months) | $180 | $2,400 |
| Fulfillment setup / monthly admin fees | $0 | $600+ |
| Interest on capital (10% APR, 6 months) | $185 | $2,975 |
| Carrying cost of unsold inventory | Minimal — small run | Potentially catastrophic |
| TOTAL CASH OUT | ~$7,765 | ~$65,000+ |
* Assumes $0.60/unit ingredient cost, standard market freight and storage rates, and 10% APR on borrowed capital. Fulfillment admin fees vary widely — many large 3PLs charge $200–500/month in platform fees regardless of order volume, plus pallet fees, receiving fees, and account minimums. If your product isn't moving, those fees compound fast.
What $48,700 buys you instead:
Paid social campaigns that prove channel fit. Influencer partnerships. Retail broker fees. Trade show presence. A sales rep. Market research. Six months of operating runway. Or simply: the knowledge that your product works before you bet everything on it.
What we need
before we run.
These are not suggestions. Every item below must be in place before Overgang schedules or runs any production.
Signed MSA
A Master Service Agreement must be signed before any production is scheduled. This protects both parties. No MSA, no run date.
COAs on-site
Certificates of Analysis for all ingredients must be physically on-site at Overgang before we run. Ship them with your ingredients or ahead of them. No COA, no run.
Allergen declaration
A complete allergen declaration for your product is required before production. Non-negotiable. Submit this with your spec sheet.
Spec sheet and blending instructions
Total pounds to be blended, percentage formulations for each ingredient, and your lot/expiration date format. Must be submitted before your run date.
Materials on-site before run day
All bulk powder and roll stock must arrive at 2114 Washington St NE, Minneapolis MN before your scheduled production date. Late materials = 50% day-rate charge for our team's downtime.
14-day lead time
Current scheduling lead time is approximately 14 days from confirmed specs and materials on-site. Plan accordingly — especially around your film's 10–12 business day print lead time.