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The "Stick Pack" Reality Check: Why You Can’t Have It... Yet.
THE TRUTH
Stick Packs vs. Reality
Want a stick pack? If you’re filling by hand or need fewer than 10,000 units, the answer is "not yet." Stick packs require specialized automation. For small-batch launches, the Flat Pouch (Sachet) is your best friend.
We get the call every day.
“I’m launching a new electrolyte powder. I love that slim, sleek stick pack look. I want to order 100-500 of them and fill them in my kitchen/commissary.”
Our answer? No. And we’re saying it because we love you.
If you’re currently hand-filling your product, the stick pack is your "final boss." You aren't ready for it yet, and that’s okay. Here is the cold, hard truth about the world's most popular on-the-go form factor
- You can’t fill a stick pack by hand.
Imagine trying to pour a teaspoon of fine powder into a drinking straw without spilling a drop. Now imagine doing that 1,000 times. A stick pack is essentially a narrow tube. It is designed to be formed, filled, and sealed in one split-second motion by a vertical machine (VFFS). If you try to hand-fill a pre-made stick pack, you will spend more on spilled product and labor than you did on the packaging. Besides, there's no way for us to "pre-form" a stick.
- The "MOQ" Wall.
Because stick packs are made from Rollstock (big rolls of film) rather than pre-made bags, the minimum order quantities (MOQs) are much higher. We aren't being mean—it’s just the physics of the printing press. If you aren't ready to commit to 5,000-10,000+ units, the stick pack isn't your friend.
- The "Co-Packer" Requirement.
Unless you have $50k+ to drop on an entry-level stick pack machine, you need a Co-Packer. And most Co-Packers won't even talk to you unless you’re bringing them enough volume to keep their machines running for a full shift. Now once you get there you will enjoy an amazing unit cost - but you need the scale and the filling equipment.
"But I still want that form factor!"
If you answered "Yes" to any of the following, we need to talk about the Flat Packet (Sachet) instead:
- I am filling by hand.
- I want less than 5,000 units.
- I don't have a specialized co-packer or internal filling equipment.
The 3-Side Seal Flat Pouch (or Sachet) is the "Growth Phase" hero. It gives you the single-serve convenience, it's much easier to fill by hand or with basic equipment, and we can print them in small batches that won't break your bank.
Quick Hits: Stick Pack FAQ
Can I fill stick packs by hand?
Technically, you could. But we don't know would form empty stick packs with one end open. It's just not sold by printers and flexible packaging manufactures.
What is the MOQ for stick packs?
Because they require rollstock production, MOQs usually start at 10,000+ units. If you need a smaller run (under 5,000), a custom sachet is your best bet.
Stick Pack vs. Sachet: What's the difference?
A stick pack is a narrow tube for automation; a sachet is a rectangular flat pouch. Sachets offer more branding space and are much easier for emerging brands to manually fill.
