Packaging Formats

Our primary packaging formats can be found listed below, however if you have a unique concept or specific requirement in mind, speak to us today as our team will always be happy to discuss bespoke solutions. Additional formats are also available through our Partnerships as Part of the Wellma Group

Available in a wide range of sizes with either 3-side or 4-side seal configurations.

Flat sachets remain one of the most versatile and cost-effective formats for powdered supplements and are ideal for single-serve applications including hydration products, collagen blends, wellness shots, daily nutraceuticals, pre-workouts and protein supplements. Available in a wide range of sizes and seal configurations.

Features can include:

• Tear notches for convenience
• Premium laminate and foil structures
• Sustainable material options
• High-quality retail-ready print finishes
• Entry-level MOQ options for emerging brands and specialist products

This format continues to be extremely popular for travel-friendly and sample-focused product launches.

One of the fastest growing supplement formats in the wellness and active nutrition market, stick packs provide a sleek, modern and highly convenient solution for single-serve powdered products.

Ideal for hydration blends, collagen products, greens powders, nootropics, electrolyte systems, GLP-1 support products and daily wellness supplements, stick packs are designed for easy on-the-go consumption and excellent consumer compliance.

Our stick pack capabilities include:

• Multiple width and fill volume options
• High-speed automated filling
• Premium print finishes and branding opportunities
• Easy-open tear formats
• Sustainable laminate developments where suitable
• Ideal portability for gym, travel and lifestyle markets

Stick packs are particularly popular for brands looking to create premium, convenient and socially marketable product formats.

Sleek, slim & highly portable. increasingly popular format for liquid supplements, gels and syrups.

Suitable for:

• Energy gels
• Electrolyte concentrates
• Wellness shots
• Functional syrups
• Nootropic and focus products
• Fast-acting carbohydrate systems

Available with multiple width options, fill volumes and top shapes. Including tear retain tops for environmentally conscious brands.

Our modern liquid stick filling lines have been specifically designed to utilise next-generation packaging laminates that help reduce excess plastic usage whilst supporting future recyclable and more sustainable packaging developments.

Available from approximately 200g through to 2kg+ capacities for powdered supplements and bulk nutrition products.

Suitable for:

• Protein powders
• Meal replacement systems
• Hydration blends
• Greens powders
• Recovery products
• GLP-1 companion nutrition products
• Functional wellness blends

Features can include:

• Resealable zip closures
• Tear notches
• Easy-open laser scoring (subject to MOQ)
• Scoop inclusion
• Premium print finishes
• Matte, gloss and soft-touch effects
• Recyclable options

Our modern semi-automatic and fully automatic filling lines are capable of supporting both specialist small runs and large-scale commercial production volumes efficiently.

Ideal for larger serving liquid products including energy gels, syrup systems, concentrated wellness products and refill applications.

These stand-up liquid pouches can include:

• Twist-off dispensing spouts
• Multi-serve functionality
• High-barrier hygienic laminates
• Lightweight, reduced-packaging formats

A growing trend within both sports and wellness nutrition markets, these packs offer convenience whilst reducing packaging weight compared to rigid formats.

More often than not, our customers require the primary pack format to be packed in to an SRP, carton, box or other secondary pack. Calleva have the expertise and capabilities to provide both the secondary packaging from our trusted print partners and pack off the products to a retail-ready format to go straight in to the distribution chain. We will work with you to size all packaging correctly and were required validate suitability with transit tests, CAD samples and press proofs.

If printed/retail ready secondary packaging isn’t required, or you assemble elsewhere then we can supply in sturdy, bulk/loose format shippers.

All of our filling and packing formats are also available as contract filling-only services for customers supplying their own bulk powder or liquid products.

In these cases, the product contents are typically free-issued to Calleva Nutrition whilst we continue to supply and manage the packaging materials and filling operation.

This service is subject to MOQ requirements and compatibility assessments to ensure suitability within our manufacturing and packing environment. Speak to us today for more information.

For customers not requiring a complete retail-ready solution, Calleva Nutrition also offers bulk manufacturing services.

Bulk supply formats typically include:

• 20kg / 25kg powder sacks
• Bulk fibre drums
• 1000 litre liquid IBCs / Pallecons
• Intermediate production formats for onward filling

This option is ideal for international brands, co-pack partners and businesses with their own filling operations.

Calleva Ingredients

Did you know we also offer bespoke ingredient solutions through Calleva Ingredients ? Visit the Calleva Ingredients website for more information, or speak to us today.