Stick packs and single-serve sachets are individually sealed single-dose pouches. They address a real friction point with powdered and some capsule supplements: portion measurement and portability.
A consumer scooping powder from a tub gets inconsistent dosing and a product that is inconvenient to travel with. A pre-measured stick pack solves both at once, which is a large part of why the format has grown fastest in powdered pre-workout, greens, and electrolyte categories.
Stick pack production runs on form-fill-seal equipment, a fundamentally different process from bottle filling and capping. A brand moving from bottle to stick pack is changing its manufacturing process, and often its manufacturing partner.
That is a genuine capability question worth confirming early. Not every co-packer that fills bottles also runs form-fill-seal stick pack lines.
Individual sealing, per-dose film consumption, and the specialized equipment involved mean stick packs typically cost more per dose than the equivalent bulk product in a bottle, sometimes meaningfully more. Brands generally price this into a premium or convenience position.
A stick pack's small surface area concentrates brand messaging and required label content, ingredient panel and dosing instructions included, into a tighter space than a bottle label allows. Clear hierarchy and minimal unnecessary copy matter more here.
Barrier film selection follows the same oxygen and moisture sensitivity logic as any other flexible packaging. For the underlying principles, see Barrier Properties 101.
Confirm barrier film structure and line capability before committing to a format change, so the manufacturing shift does not surprise a program mid-planning.
Request a quote on the fill weight, barrier requirement, and annual dose count.