Custom Stick Packs

Will my sample stick pack match the bulk order?

Yes, more closely than most suppliers. Many factories proof on a digital printer, which drifts from the final result. We proof on the same production process that runs your bulk order, so the sample matches the production result with only minor batch variation. Our sample fee is a little higher for that reason, and it's worth it.

Which material gives the longest shelf life?

Classic with High Barrier gives the longest shelf life. Classic is metallized for strong moisture and oxygen protection, and High Barrier adds a foil layer for the most sensitive contents like supplements and freshness-critical powders. Recyclable and Compostable suit shorter shelf-life or lighter-protection products.

What sizes do stick packs come in?

Stick packs come in narrow standard sizes built for single servings, such as 1.6 x 5 inches, and you can set a fully custom size for your exact fill (in inches or millimeters). We fully customize dimensions, so build your size in the 3D quote tool and see the price instantly.

What's the minimum order for custom stick packs?

100 units. That's low enough for a first launch or market test, with wholesale and bulk pricing as you scale. The unit cost drops at each quantity tier as you build your order.

What products are suitable for the PCR Material option?

The PCR Material option is best suited for lightweight dry products such as coffee, snacks, powders, and dry pet food, with a recommended filled weight of up to 1 kg. It is not recommended for liquids or heavy-duty applications. Final suitability depends on the product, filling conditions, and packaging requirements.

What is the PCR Material option?

PCR stands for post-consumer recycled. Our PCR Material option replaces the standard PE layer with an 80 μm PE layer containing 50% post-consumer recycled content, helping reduce the use of virgin plastic. It is available with eligible Classic and Recyclable structures. Eligible pouch structures contain approximately 30% PCR by total finished-package weight. The final percentage varies based on the selected structure and components and can be confirmed for the final pouch specification.

What is a stick pack?

A stick pack is a narrow, tube-shaped single-serve pouch with a back seam seal, also called a stick pouch or powder stick. It uses less material than a rectangular sachet and slips easily into a pocket or bag, which makes it the go-to for powdered drink mixes, electrolytes, collagen, protein, probiotics, supplements, and sweeteners. Both powders and liquids work in a stick pack.

What if my stick packs arrive damaged or wrong?

Reach out to our team within 24h of delivery. If the order is damaged, defective, or doesn't match the approved proof, we'll review it and make it right.

Stick pack or flat pouch (3-side seal): which should I use?

Choose a stick pack for free-flowing powders and liquids in a single serve, like drink mixes, electrolytes, and supplements, where the slim, pour-friendly tube is the point and you want a premium single-dose feel. Choose a flat pouch, the three-side seal sachet, for wider or flatter contents like creams, masks, wipes, and sample sachets, and when you want two full panels for branding. Stick packs also use roughly 10 to 40 percent less film than an equivalent rectangular pouch, so they can lower material cost at volume.

Should I order pre-made stick packs or roll film (rollstock)?

It comes down to your filling setup and volume. Pre-made stick packs arrive already formed, so you or your co-packer just fill and seal them, which suits lower volumes, hand or semi-automatic filling, and test launches. Roll film, also called rollstock, is printed film on a roll that feeds a VFFS (vertical form-fill-seal) machine, which forms, fills, seals, and cuts the packs in one continuous high-speed run, best for higher volumes and automated lines. If you work with a co-packer, check which format their machine takes before you order.

Matte, gloss, or soft touch: what lamination can I add?

All three. Matte gives a smooth, low-glare finish, Gloss gives a shiny, vibrant finish, and Soft Touch Film gives a velvety, premium feel. Lamination sets the surface look and feel of the finished stick.

How much do custom stick packs cost?

Price depends on size, order quantity, format (pre-made or roll film), material and barrier level, lamination, finishing effects, a tear notch, and shipping. Larger quantities lower the unit cost, while High Barrier and added finishes raise it. The 3D quote tool updates your landed price live as you build, so there are no surprises.

How long do custom stick packs take to make and ship?

Production takes 7 to 12 business days after proof approval. Shipping then depends on your tier: Express is fastest at about a week, with Priority, Standard, and Economy at lower cost and longer transit. Exact timelines show as you build your order.

How do I choose the right material for my stick pack?

Start with what matters most. Classic is a metallized film with the strongest moisture and oxygen barrier, the safe pick for sensitive or premium powders. For the most demanding contents, turn on High Barrier, which adds an aluminum foil layer for even stronger protection. Choose Recyclable if a recycling-friendly direction matters to your brand: a mono-material PE film with an EVOH barrier, designed for the PE recycling stream. Choose Compostable if sustainability storytelling matters most: kraft and PLA for products with lighter protection needs.

How closely does the 3D preview match the finished stick pack?

Closely. It's a true-to-spec view of your size, material, finishing, and artwork, and a reliable guide for decisions. Small color and finish differences can still appear in print, so order a custom sample to confirm the exact look before a full run.

How accurate is the stick pack or roll film length?

We build a 5 to 10 percent material allowance into the length, so the finished length can vary a little within that range rather than landing on an exact millimeter. That allowance keeps the form-fill-seal process running cleanly. If your fill needs a precise length or repeat, confirm it with your co-packer, who knows the exact settings of your VFFS machine, before you finalize the design.

How accurate are the printed colors on custom stick packs?

We match to spec with CMYK and Pantone references, so your brand colors stay consistent across runs. Screens and print can differ slightly, so order a custom sample if exact color is critical.

Does PCR material make a pouch recyclable?

Not necessarily. PCR describes the recycled content used in the pouch, not whether the finished package can be recycled. Classic pouches with PCR remain multilayer packaging and are not recyclable. For a structure designed for PE recycling streams, choose the Recyclable material option and enable With PCR. Actual acceptance varies by location and recycling program.

Can I see what my stick pack will look like before I order?

Yes. The 3D preview applies your size, material, lamination, finishing, and artwork to the actual stick, so you can rotate it and review the finished look before committing.

Can I reorder the same stick pack design later?

Yes, in one click. Your approved designs are saved to your account, so repeat runs use your locked specs and artwork with no rebuilding or re-proofing. Pricing reflects the new quantity and options you choose.

Can I order a sample stick pack before placing a full order?

Yes. A custom sample is made with the same material, printing, and finishes as your full order. It arrives in about two weeks, and you also get 10 white-background product photos around Day 10, so you can start marketing before it lands.

Can I design my stick pack without a dieline?

Yes. Use the 3D quote tool to build the stick pack and your options, then upload artwork. If you already have a dieline or finished art, upload it directly. You don't need to understand every file requirement to move forward.

Can I add finishing like Spot UV or Hot Foil?

Yes. The Finishing Effects let you make specific areas stand out: Spot UV adds glossy highlights on areas like your logo, while Hot Foil adds a metallic shine. These sit on top of your full-color print for a premium accent.

Can I add a tear notch for easy opening?

Yes. A tear notch is a small cut at the seal that lets customers tear the stick open cleanly by hand, no scissors needed. It's the one structural add-on most stick packs use, and it's worth it for an on-the-go single serve.

Can I add a clear window to show the product?

Yes. A clear window, set in the Finishing Effects, lets customers see the powder or product inside, which works well for colorful drink mixes. Skip it if your product is light-sensitive or you want full-coverage print across the panel.

Are stick packs food-safe?

Yes. The inner layers are designed to meet FDA food-contact requirements, and ink is printed outside the food-contact surface, away from your product. FDA food-contact compliance documentation is available in the Product Details section.