Items for each bag

Protein source (such as a microwavable pasta meal, single serving soup/stew, or tuna lunch)
Granola bar
Beverage (real fruit juice in juice box or Capri Sun)
Crackers with cheese or peanut butter
Applesauce or individual fruit cup
Spoon
Napkin
1 gallon-sized Ziploc-type bag (to put items in)

Notes

Put each lunch in a gallon sized Ziploc-type bag
All expiration dates should be at least 3 months from date of purchase.
Total cost for materials for 40 lunches in November 2007 at ShopRite was about: $90.00 ($2.25/lunch)
Total cost for materials for 100 lunches (easier than 85) in January 2010 at ShopRite is $228.36 ($2.28/lunch).
Total cost for materials for 50 lunches in September 2010 at ShopRite is $122.38 ($2.45/lunch).

We typically purchase the following supplies from Dollar Tree and Minimus.biz

Contents each kit (lowest price source in parentheses)

Notes

Put all items into a gallon Ziploc-type bag.
Small travel-size items work best.
Include the feminine hygiene products in 1/3 of bags. We put these into smaller ziploc bags.
Make sure toothpaste expiration date is at least 3 months from date of purchase.
It took us less than 10 minutes to assemble 40 kits at the end of a youth group meeting.
Total cost for materials for 40 kits in April 2007 was $93.78 ($2.35/kit)
Total cost for materials for 40 kits in January 2009 was $95.56 ($2.39/kit)
Total cost for materials for 40 kits in April 2009 was $87.35 [$67.35 (Minimus) + $20.00 (Dollar Tree)] ($2.18/kit)
Total cost for materials for 20 kits in January 2010 was $49.80 [$33.80 (Minimus) + $16.00 (Dollar Tree)] ($2.49/kit). Cost per kit is slightly higher due to upgraded shampoo (bottle instead of packet) and toothpaste (tube instead of packet).
Tom is the shopper for these items

Continually evolving shopping list (20 kits)