Custom Sachets & Stick Pack Packaging

A sachet is a flat rectangular pack sealed on three or four sides, suited to powders, granules, liquids, gels, and creams from samples to single servings. A stick pack is a long narrow tube with end seals, designed to pour a dose cleanly into a bottle, glass, or directly into the mouth—common for drink mixes, electrolytes, and nutrition powders. Stick packs typically use less film per dose and pack densely, while sachets offer more artwork space and a familiar tear-open experience. Both are formed from printed rollstock on form-fill-seal equipment, so the machine defines much of the specification.

• Sachets: flat three- or four-side-seal single-serve packs
• Stick packs: narrow pour-friendly tube format
• Formed from printed rollstock on packaging equipment
• Dose, opening behavior, and film specified with the machine

Drink mixes, electrolytes, supplements, instant coffee, spices, sauces and condiments, personal-care samples, and pharmaceutical-adjacent products all run in single-serve formats, but each combination of product, dose, and use pattern points to a different pack. Powder flow, particle size, liquid viscosity, tear or cut opening, and where the consumer uses the product—on the go, in a kitchen, at a gym—drive format, dimensions, and opening features.

Single-serve formats are defined by the machine: web width, print repeat, lane count, eye marks, cutoff, seal style, and coding position all follow the equipment specification. Provide the machine make and model, target pack dimensions, dose, line speed, and the co-packer's approved roll specification early—artwork and dielines should be built on the confirmed web layout, not before it.

A single-serve pack is opened once, so seal integrity and opening behavior carry the experience. Moisture-sensitive powders need tight barrier and dust-controlled seals; liquids need compatible sealants and leak performance; tear notches, laser scoring, and cut direction determine whether the pack opens cleanly at the point of use. Validation typically includes seal, leak, drop, and line trials plus filled-pack checks against the dose.

Small formats compress branding, mandatory copy, and coding into limited space across multiple lanes. Plan minimum type sizes, barcode placement and quiet zones, lot and date coding areas, and lane-to-lane registration with the dieline, and coordinate retail cartons, counter displays, or variety packs so the single-serve pack and its shelf container work as one system.