OMAG: Packaging for nutraceuticals – greater flexibility, less waste

Designing the right format means improving productivity, sustainability and the final user experience at the same time.

The challenge

A few weeks ago, we successfully completed the FAT of a complete packaging line designed for sports nutrition products, including protein and supplement mixes.

The goal of the project was to develop a flexible and precise packaging solution while optimizing material consumption.

For this specific application, the sachet content varied in both quantity and composition: not only capsules and tablets, but also gel formulations, which require extra attention to avoid product dispersion during handling.

The customer requested different sachet sizes depending on the product count, ranging from 4 to 9 units per pouch.

Another key requirement was to make each pouch as compact as possible in order to optimize film consumption and achieve a double advantage:

• reduced material usage and cost savings for the manufacturer
• lower packaging waste from an environmental perspective

The solution

A 4-side sealed sachet packaging solution was implemented, including several process optimizations:

• machine adjustment to minimize product contact during the falling phase, reducing dispersion risks, especially for gel products
• differentiated pouch formats based on content quantity, allowing material savings without compromising functionality
• transparent upper section of the pouch to ensure product visibility and immediate integrity check

Added value

Beyond production efficiency, the project also introduced a more sustainable packaging approach:

• reduced film waste thanks to modular pouch sizing
• possibility of using films containing recycled materials
• improved balance between product protection and process efficiency

In nutraceuticals packaging, flexibility is not an option – it is a requirement.

This article was originally published by OMAG.