(01)
Backed by Science
(02)
Sourcing with intention
(03)
Quality Assurance
(04)
Production & Packaging
Years of refining and perfecting our process - we’re happy to introduce you to the process we call “The LEWA Formula.” While there may be slight variations depending on what we’re producing - whether it’s our groundbreaking functional pouches, a range of nicotine products, or contract manufacturing for a partner - this is our A-to-Z approach to pouch making.
Backed by Science
From idea to dosage, every Lewa product is shaped by research,
evidence, and strict standards.
Grounded in Quality
Sourcing is where function meets quality. We work only with trusted partners and apply strict criteria to every ingredient, creating formulations that perform as well in practice as they do on paper.
Sourcing with Intention
Fabio and his father, yerba mate farmers in Brazil, have been with us since our first launch in 2020. Finding the right suppliers has meant years of travel, testing, negotiation, and ongoing evaluation. From Brazil to Europe, every partner is carefully chosen to meet our standards for quality, reliability, and transparency. Some, like Fabio, have become more than suppliers - they’re part of our journey.
Certified organic production
Sustainable, smoke-free drying
Full traceability from farm to pouch
Built on Criteria
For any functional concept, the list of potential ingredients is nearly endless. Take POWER, for example - there are countless options of amino acids, nootropics, vitamins, and minerals that could be utilized. But with only 600 mg of space in a pouch, every ingredient has to fight for its place. Only three make the cut, which means the selection process is rigorous.
Defined by Detail
Every product is tested, refined, and verified before reaching full-scale production. From blending and pH testing to moisture control and peer evaluation, each step is designed to secure consistency, safety, and the best possible user experience.
Blending
Forming the Foundation
Once the dry ingredients are mixed, the liquid phase - mainly flavor, humectant, and water - is added. The full blend is then transferred to a specialized mixer and blended thoroughly for 15-20 minutes.
From there, it’s poured into the production line to begin pouch filling. The blend is portioned into pouches, sealed in cans just like in full-scale production, and for test batches, cans are hand-marked instead of labeled.
liquid phase
pouching
Quality Testing
Testing for Consistency
We begin by testing pH - a critical step to ensure the pouch is gentle on the gums and free from irritation. Just as important, the acid–alkaline balance must remain within the optimal range for mucosal absorption, as many functional compounds are only effective at specific pH levels.
Next, we measure moisture content - a key factor in how the pouch feels, releases, and holds up over time. Proper moisture supports a pleasant mouthfeel, controlled ingredient release, and the shelf life of the product.
pH-testing
moisture
Iterations
Refined Through Iteration
If the baseline product passes internal review, we move into peer testing - creating small-batch iterations with subtle adjustments to sweeteners, aromas, and overall flavor balance. This is where a product begins to take on personality, exploring different expressions of the main flavor profile, such as sour apple, apple & cinnamon, apple mint, or apple & ginger. Each variation is evaluated by our team for taste, mouthfeel, and controlled release.
Once the variations are ready, a selected group of peers evaluates each version blindfolded - with no knowledge of which formula is which. Every sample is scored against key metrics like flavor quality, mouthfeel, aftertaste, and overall experience.
flavoring
evaluation
Designed for impact
Before a product reaches full production, we finalize essential steps - from regulatory documentation to label design - ensuring it’s compliant, market-ready, and visually distinct.
Compliance Secured
With the final recipe approved, we move into post-testing procedures. This includes preparing all required documentation, such as safety data sheets (SDS) and regulatory materials. These steps ensure every product meets both our internal standards and external requirements before entering the market.
Design in Motion
Every label is crafted to balance flavor, function, and brand clarity - bold, precise, and built to stand out.
Identity Defined
Next comes the label. Artwork is developed to reflect the product’s flavor, concept, and functionality. With limited space on the can, every detail counts - designs must be bold, clean, and instantly recognizable across the lid, sides, and bottom, without losing clarity or impact.
final steps
From Line to Pallet
Production and packaging mark the final step - where every tested formula becomes a finished product, ready to be shipped with consistency and care.