Stick packs and sachets are both excellent single-serve packaging formats — but they're designed for different applications, different equipment, and different consumer experiences. Choosing the wrong one can create production problems, cost overruns, or shelf-impact issues that are expensive to reverse.
Here's how to make the right call before you commit.
What is a stick pack?
A stick pack is a narrow, elongated single-serve pouch — typically 15–30mm wide and 80–150mm long. It's formed from a single web of film on a vertical form-fill-seal (VFFS) machine, then filled and sealed.
Stick packs are ideal for: - Free-flowing powders (protein, collagen, electrolytes, fiber, coffee) - Granular products (sugar, salt, specialty seasonings) - Applications where the consumer tears open and pours or mixes
The narrow format makes them easy to carry, fits naturally in pockets or bags, and presents well in display boxes. They're a standard format for sports nutrition, nutraceuticals, and on-the-go beverage applications.
What is a sachet?
A sachet is typically wider and shorter than a stick pack — more of a square or rectangular pouch. It can be produced on VFFS or horizontal form-fill-seal (HFFS) equipment depending on the product.
Sachets are better suited for: - Creams, gels, and semi-viscous products (skincare, condiments, sauces) - Liquid fills at low volumes - Products where the consumer squeezes rather than pours - Applications requiring a tear notch for easy opening
The wider format allows more surface area for branding and ingredient lists, which matters for regulated categories like cosmetics.
The three questions that determine the right format
1. What is the viscosity of your product? Free-flowing powder → stick pack. Semi-viscous or liquid → sachet. 2. What is the consumer end-use? Mix into a drink → stick pack. Apply topically or squeeze onto food → sachet. 3. What are your volume and run requirements? Stick pack lines typically require minimum run sizes of 10,000–15,000 units to justify setup. Sachets can run in smaller batches on some equipment.
A note on materials
Both formats can run on foil laminate, paper laminate, or clear film depending on your barrier requirements. If your product is moisture-sensitive or requires an oxygen barrier, make sure your co-packer specifies appropriate laminate structure — it significantly affects shelf life.
If you're not certain which format is right for your product, a 30-minute conversation with our team can usually get you to a clear answer — and we can provide samples of both formats in your category for comparison.