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Stick Pack Manufacturers

Last updated: January 2026

This directory lists 90 stick pack manufacturers across the United States, from high-volume pharmaceutical co-packers with aseptic filling capabilities to specialized boutique firms focused on organic nutraceutical powders.

Buyers turn to stick pack manufacturers to solve challenges ranging from achieving precise micro-dosing for active pharmaceutical ingredients (APIs) to ensuring robust Fin Seal integrity for hygroscopic nutraceutical powders. The need for consistent fill accuracy across millions of units, coupled with selecting the correct multi-layer barrier films to extend product shelf-life and maintain efficacy, drives the search for specialized partners.

The diverse landscape of stick pack suppliers spans large-scale contract manufacturers serving established CPG brands, who typically offer multi-lane Form-Fill-Seal (FFS) lines and extensive warehouse logistics, to smaller, agile co-packers. These niche providers often excel in lower volume runs, specialized organic certifications, or handling challenging product types like high-viscosity gels or temperature-sensitive probiotics, offering greater flexibility and customisation for emerging brands.

90 companies·64 emails·83 phones

Company Directory

90 companies nationwide

Green Bay, WI

Based in Green Bay, WI, American FlexPack provides contract packaging services, specializing in single-use sachets and fluid-filled pouches for various viscosities. They offer custom packaging solutions to industries like health and beauty, automotive, and nutraceuticals, ensuring high-quality production from their in-house facility.

Bloomingdale, IL

Based in Bloomingdale, IL, Assemblies Unlimited, Inc. is a turnkey contract packaging and co-packing provider. They specialize in packaging powders, beverages, oils, and supplements into various formats, including pouches, bottles, and sachets. The company offers quick turnaround services across multiple US plant locations.

Hauppauge, NY

Based in Hauppauge, NY, Bactolac Pharmaceutical is a contract manufacturer specializing in turn-key nutritional supplements and vitamins. With over 30 years of experience, it provides comprehensive in-house services, from product development to expert stick pack packaging solutions for health products.

Los Alamitos, CA

Based in Los Alamitos, CA, BAM Packing, Inc. provides contract packing services, notably specializing in stick pack filling. They handle tea, dry food products, and instant beverages, also offering stand-up pouch and sachet filling. The company is CGMP, USDA Organic, and Kosher certified, serving the food and beverage industry.

Denver, CO

Based in Denver, CO, Basecamp Co-Pack is a co-packing and food manufacturing company. They specialize in batch and bulk blending, providing customized solutions for projects of all sizes. Capabilities include food and bar manufacturing, with a focus on powder filling services, catering to various co-packing needs.

Shawano, WI

Based in Shawano, WI, Belmark provides diverse packaging solutions, specializing in stick pack packaging. Their offerings are designed to enhance brand visibility and drive purchases in various retail environments, including grocery stores, big-box retailers, and specialty shops.

Bison Bag specializes in custom stick pack packaging solutions for single-serve pouches. They manufacture packaging for powders, liquids, and supplements, offering multiple sizing and printing options. The company operates an SQF certified facility equipped with advanced printing presses.

Alvin, TX

Based in Alvin, TX, BlendPack LLC offers custom blending and packaging services for powder chemicals and additives. They provide one-stop solutions, including automated small-size packaging, repacking from various containers to bulk, and computer-generated labeling. The company also offers warehousing, distribution, and operates a fully equipped production facility near Houston's ports.

Fresno, CA

Based in Fresno, CA, CalPack is a full-service contract packaging company specializing in stick packaging services. They offer vertical form fill seal solutions for a variety of products including powders, granules, liquids, and gels. Serving diverse industries like food, nutritional, and pharmaceutical, CalPack provides comprehensive packaging solutions.

Rockaway, NJ

Based in Rockaway, NJ, Carolan Packaging provides contract packaging, filling, labeling, and automated assembly services. They leverage extensive industry knowledge to offer dependable fulfillment solutions for various product types. The company is a reliable partner for comprehensive packaging needs.

Oconomowoc, WI

CLD Graphics, based in Oconomowoc, WI, specializes in producing custom stick pack packaging. The company utilizes advanced digital and flexographic printing techniques to create packaging with bold graphics, high-barrier protection, and production-ready functionality for various products.

Consolidated Strategy Group offers complete packaging solutions, including turnkey components, packaging, and product filling services. With over 40 years of experience, they specialize in filling various formats such as stick packs, bottles, jars, and bags for industries like beauty, pharmaceutical, and food.

Torrance, CA

Based in Torrance, CA, Cosmopak is a full-service private label and contract manufacturer for cosmetic and personal care products. They provide comprehensive solutions from product development and formulation to packaging. Their extensive filling capabilities explicitly include stick pack manufacturing for skincare, body care, and color cosmetics.

DazPak Flexible Packaging provides comprehensive packaging solutions for innovative brands, specializing in nutraceuticals and powdered mixes. The company offers printing, laminating, and converting services for high-barrier roll stock, ensuring airtight performance and vibrant graphics. They focus on quick and effective product launches for their partners.

Dallas, TX

Based in Dallas, TX, Divine Design Manufacturing is a contract manufacturer specializing in supplement production and packaging. The company offers powder blending, capsule, tablet, liquid, softgel, and notably, stick pack manufacturing. They provide comprehensive solutions including labeling, packaging, and kitting services for the supplement industry.

Vista, CA

EcoPackables is a Vista, CA-based manufacturer specializing in sustainable flexible packaging. The company provides custom packaging services, including high-quality branding and various laminate material options. They offer B2B clients custom and bulk orders, showcasing their manufacturing capabilities through sample packs.

Kaufman, TX

Based in Kaufman, TX, ELIS Manufacturing & Packaging Solutions provides end-to-end contract manufacturing for nutraceuticals and consumables. Services include tailored blending, precise filling, and custom packaging, explicitly mentioning stick packs. They also offer printing, kitting, warehousing, and shipping solutions from concept to consumer.

Los Angeles, CA

Based in Los Angeles, CA, Elk Packaging offers custom packaging solutions for brands in industries like food and nutraceuticals. They provide stick packs, pouches, folding cartons, wrappers, and sachets. The company focuses on efficient design, quality materials, and tailored solutions to elevate brand image.

Union City, CA

Based in Union City, CA, Emerald Packaging is a flexible packaging manufacturer founded in 1963. They provide a range of solutions including roll stock, bags, pouches, and lidding. A leading produce packaging supplier, the company focuses on innovation and sustainability, offering advanced Post-Consumer Recycled (PCR) packaging.

Aventura, FL

Based in Aventura, FL, Fox Packaging designs and manufactures a variety of flexible packaging solutions, including poly, combo, and stand-up pouch structures. The company emphasizes sustainable options, offering packaging with up to 30% post-consumer recycled content. They serve the agricultural sector and provide packaging automation solutions.

Menomonee Falls, WI

Based in Menomonee Falls, WI, Glenroy manufactures custom flexible packaging solutions, including stick pack packaging. They provide reliable lamination and rollstock flexible packaging designed for strength, style, and consistency. Glenroy serves various industries with their specialized packaging capabilities.

Vernon, CA

Great American Packaging, based in Vernon, CA, custom manufactures flexible packaging solutions including poly bags and films. Utilizing form-fill-and-seal technology, they produce packaging for food, ice, medical, and consumer applications. The company is IFS PACsecure certified and has been operating in the USA since 1966.

Huntington Beach, CA

Based in Huntington Beach, CA, HTT Pack offers contract filling and packaging solutions for single-use stick and sachet packets. They utilize their own machinery to pack both powder and liquid products, including seasonings, nutrition powders, sauces, and honey. Packets come in various customizable shapes and dimensions.

Carrollton, TX

Based in Carrollton, TX, IBR Packaging specializes in flexible packaging solutions, including stick packs, pouches, and sachets. The company provides co-packing services for consumer packaged goods across industries like food, supplements, cosmetics, and OTC drugs. They handle both small pilot runs and large-scale production.

Mcallen, TX

Identipak, based in McAllen, TX, provides innovative contract packaging solutions for beauty, personal care, wellness, and food & beverage brands. They specialize in filling and packaging various products into classic, diecut, and tandem sachets, tubes, bottles, and vials. Services include turnkey private label solutions.

Sebastian, FL

Based in Sebastian, FL, IMPAK Corporation manufactures and supplies flexible packaging, specializing in StikPAK® stick pack pouches. These elongated, tube-shaped pouches feature a fold-over side and tear notch, designed for efficient product dispensing across various industries. The company provides direct manufacturing services.

San Diego, CA

Based in San Diego, CA, Intelligent Blends is a custom manufacturer specializing in private label stick packs for coffee, tea, and functional beverages. They provide turnkey services, including blending, roasting, formulation, and diverse packaging. The company excels at packing a wide variety of powders and ingredients into convenient stick pack formats.

Woodland, CA

Based in Woodland, CA, Interpac Technologies, Inc. is a co-manufacturer specializing in food packing for wet and dry goods. They provide comprehensive solutions including custom blending, packaging, warehousing, and distribution. Their versatile services encompass bottling, cup and bag filling, and pouch forming for various flexible packaging requirements.

Totowa, NJ

Located in Totowa, New Jersey, JJM Packaging is a 3rd party SQF-certified co-packer. They specialize in manufacturing dry food, powder, grain, and supplement products, offering a wide range of packaging solutions including stick packs, pouches, K-cups, and canisters. Services cover formulation, blending, and packaging.

Milwaukee, WI

Based in Milwaukee, WI, Jonco Industries provides contract filling and packaging services for liquid and gel products. They ensure fast package filling with low waste and quick turnaround, making them a direct provider for stick pack manufacturing and other flexible packaging solutions.

Dallas, TX

KPAK, based in Dallas, Texas, specializes in comprehensive stick pack custom packaging and filling services. With over 35 years of experience, the company provides expert contract manufacturing solutions. They focus on high-quality and efficient production, catering to commercial clients needing specialized stick pack solutions.

Boca Raton, FL

Based in Boca Raton, FL, LF OF AMERICA is a turnkey partner for Personal Care and OTC products. They specialize in packaging manufacturing, formulation, and contract filling for unit and single dose packaging. Services are performed in an ISO 8 Clean Room, adhering to Cosmetic GMP guidelines.

Based in Halethorpe, MD, Maryland Packaging is a food co-packaging and co-manufacturing company. They provide innovative packaging solutions, private labeling, fulfillment, and High Pressure Processing (HPP) services. Specializing in products like sauces, fruit bars, gazpacho, and smoothies, they streamline food production and delivery for businesses.

Maxim FlexPac provides printed flexible packaging solutions for consumer packaged goods, pharmaceutical, child-resistant, and cannabis markets. The company specializes in custom packaging and printing services, serving corporations with high-quality products. It also offers packaging laboratory services.

Indianapolis, IN

Based in Indianapolis, IN, MSL COPACK + ECOMM provides specialized contract packaging services. They address powder filling challenges and offer multi-format shrink packaging, kitting, POS display assembly, and blister packaging. The company also handles full-service retail distribution and e-commerce fulfillment for sectors including food and beverage.

Greenville, SC

Based in Greenville, SC, Multi-Pack Solutions operates as a contract packaging partner, offering customized sachet and pouch solutions for a variety of products. They specialize in tailored services, including custom pouch sizes and precise fill weights, to meet the specific packaging needs of their clients.

Bastrop, TX

Based in Bastrop, TX, Nutrabound Labs is an NSF-certified contract supplement manufacturer. They specialize in high-capacity stick pack manufacturing for powdered nutraceuticals, including hydration and pre-workout formulas. The company offers turnkey solutions for brands across the United States.

Saint Augustine, FL

Based in St. Augustine, FL, Nutra Coast manufactures nutritional supplements like powders and capsules. The company provides high-volume manufacturing with diverse packaging solutions, including stick packs, resealable bags, and sachets. Utilizing advanced equipment, Nutra Coast offers fast-turnaround services for dietary supplement brands.

Fontana, CA

Based in Fontana, CA, New Wave Converting, Inc. is a family-owned flexible packaging manufacturer with over 40 years of experience. They provide advanced technology solutions for protecting products with various flexible packaging formats, including stick packs.

Santa Ana, CA

Based in Santa Ana, CA, OC Nutra offers custom supplement manufacturing and fulfillment, specializing in powders, liquids, capsules, and stick packs. Established in 2007, they provide formulation, packaging, and labeling services, supporting brands with flexible low minimum order requirements.

Garden Grove, CA

Based in Garden Grove, CA, Aaron Thomas Company, Inc. is a contract packaging professional specializing in stick pack manufacturing, pouching, and kitting services. They provide filling for bottles, pouches, and stick packs. Certified SQF Level 2, organic, and cGMP, the company operates facilities in Los Angeles, Chicago, and Memphis.

Neenah, WI

Based in Neenah, WI, Personalized Packaging Systems manufactures custom branded stick packs, pouches, and bags. They offer printed flexible packaging solutions, product packaging design, and engineering services. The company also produces custom boxes, mailers, and printed sealing tapes, serving diverse industries from start-ups to promotional product dealers.

Lindon, UT

Based in Lindon, UT, Pharmatech Labs is a nutritional contract manufacturer specializing in liquid and powder supplements. They provide turnkey solutions including stick pack manufacturing, producing up to 150,000 packs from 23mm to 40mm. The company also offers additional packaging, kitting, and R&D services.

Fort Worth, TX

Based in Fort Worth, TX, Polymerall LLC manufactures and distributes custom printed and laminated flexible packaging solutions. They specialize in films, rollstock, bags, pouches, and Easysnap single-dose packaging. The company serves diverse markets including coffee, snack, food, pet food, and personal and household products.

Old Saybrook, CT

Premium Label & Packaging specializes in custom printed flexible packaging and innovative label solutions for diverse industries, including wellness, beauty, and food products. With six manufacturing locations, the company provides exceptional quality and personalized service, partnering with private-label companies and co-packers for tailored packaging requirements.

Anaheim, CA

ProAmpac is a flexible packaging manufacturer offering single-serve stick-pack solutions with PRO-TEAR laser scoring options. The company provides creative packaging, including ProActive Recyclable films, and enables custom flexible packaging prototypes through its MAKR by DASL platform.

Gallatin, TN

Rich Products specializes in custom packaging solutions for various ambient dry products. Their capabilities include packaging for nuts, seeds, dried fruits, vegetables, grains, baking ingredients, and spices. Based in Gallatin, TN, they provide comprehensive manufacturing services for diverse food items.

South San Francisco, CA

Based in South San Francisco, CA, Sampac Enterprises is a custom processor and tea-packer specializing in sachet packing and encapsulation services. They also provide envelope overwrap printing, tag printing, and cellophane shrink solutions, serving as a raw material supplier for various industries.

Chino, CA

Shannon Packaging Company fabricates custom flexible barrier packaging, including pouches, tubing, and sheeting, from its 50,000 sq ft Southern California facility. They handle small trials to large production runs, offering printed or unprinted solutions. Their barrier solutions protect diverse products, from food items like beef jerky to industrial materials.

Valencia, CA

Based in Valencia, CA, Simpson Laboratories is a contract manufacturer specializing in nutraceutical innovation. They provide comprehensive services for sport nutrition and general wellness products, encompassing formulation, manufacturing, and diverse packaging options. The company emphasizes its stick packet capabilities for convenient brand offerings.

Santa Ana, CA

Based in Santa Ana, CA, Soviia provides co-packing services for health and wellness products. Capabilities include blending, labeling, and filling of bottles, bags, sachets, and stick packs, with a specialization in agave-based sweeteners. The company holds ISO 9001:2008, BRC, and FSSC 22000 certifications.

Phoenix, AZ

Based in Phoenix, AZ, Spec Enterprise offers contract packaging services for powders and liquids. They provide filling into bags or bottles, with weights from 5 grams to 5000 grams. Capabilities also include tube and cosmetic filling, ingredient blending, labeling, and custom formulation, supporting diverse product packaging needs.

Roy, MN

Steuart Nutrition provides contract manufacturing services for wellness brands, specializing in scalable stick-pack production. They offer fully automated stick-pack lines with flexible sizing capabilities, alongside powder and liquid blending and filling services. The company focuses on rapid turnarounds and quality assurance for innovative clients.

Carlsbad, CA

Based in Carlsbad, CA, Stick Pack Labs is a contract manufacturer and blender specializing in stick packaging. They provide co-packing, product development, and fulfillment services for new and established brands in the food and nutraceutical industries. The company offers flexible, single-serve packaging solutions.

Rocky Mount, VA

Based in Rocky Mount, VA, Stik-Pak Solutions Inc. is a contract manufacturer specializing in modern single-serve stick packaging. As a core competency, they offer comprehensive services from concept to creation, including canister packaging, secondary packaging, and blending, to transform ideas into high-quality finished products.

Fort Worth, TX

Based in Fort Worth, TX, Southwest Packaging offers comprehensive contract packaging and co-packing services. They specialize in filling and bagging diverse products into containers like bottles, jars, and pouches. They provide turnkey solutions, managing material sourcing, filling, and distribution for private labels and brands.

Brooklyn Park, MN

Based in Brooklyn Park, MN, The Packaging Lab provides custom printed flexible packaging, including stand-up and lay-flat pouches, and custom rollstock film. They support products like drink powders and snack bars, offering rapid 24-hour turnaround times and no minimum order quantities. The company also provides design assistance and free US shipping.

Orem, UT

Based in Orem, UT, Traco Packaging manufactures diverse flexible packaging solutions. They specialize in shrink-sleeve labels, PVC shrink bands, and multi-pack bundling. Traco also produces various pouches, including stand-up, 3-side seal, and roll stock, alongside stick packs and sachets, utilizing plastic, paper, and ink with quality printing.

TrustWorks is a contract manufacturer and co-packer, providing premium packaging solutions for the supplement and vitamin industry. They offer full-service manufacturing from R&D to packaging and labeling, including in-house gummies, softgels, and capsules. They support natural, organic, vegan, and gluten-free product claims.

Elkhorn, WI

Based in Elkhorn, WI, U.S. Packaging, LLC provides contract packaging solutions. They specialize in flexible packaging, including stick packs, sachets, and single-serve pouches, utilizing vertical and horizontal form-fill-seal services. The company also offers rigid packaging and retail assembly for the food, beverage, and personal care industries.

Harlingen, TX

Based in Harlingen, TX, Valley Cold Storage & Logistics offers specialized co-packing services. They efficiently repack bulk food items into single-serve, versatile packages designed for easy reheating in microwaves, ovens, or bowls. The company also provides biodegradable packaging options for its B2B food industry clients.

Atlanta, GA

Graphic Packaging International manufactures innovative consumer packaging solutions, including stick packs, for diverse industries. They focus on helping customers launch new products with effective packaging, often incorporating sustainable materials designed to reduce or replace plastic usage.

Morrilton, AR

Based in Morrilton, AR, Brand Packaging Group specializes in manufacturing stick packs. The company provides contract packaging services for a range of products, including beverage mixes, white refined sugar, and natural raw sugar.

Rochester, NY

Unither Pharmaceuticals specializes in developing and producing pharmaceutical products, notably utilizing liquid stick-pack technology for precise unit-dose delivery. With global facilities, including a US presence in Rochester, NY, the company offers extensive experience in manufacturing various pharmaceutical forms for diverse needs.

Sugar Land, TX

Based in Sugar Land, TX, Accredo Packaging Inc. manufactures sustainable flexible packaging solutions for the Consumer Packaged Goods (CPG) segment. They produce a range of flexible formats including rollstock, various pouches, and stick packs. The company offers recyclable, compostable, and traditional packaging options from their advanced US-based manufacturing facility.

Carrollton, TX

Based in Carrollton, TX, Aegle Nutrition is a certified GMP and FDA-registered co-manufacturer offering turnkey solutions. They specialize in liquid and powder filling, producing stick packs, supplements, beverages, and energy shots. Capabilities encompass formulation, blending, bottling, and fulfillment for diverse businesses.

Brand Nutra offers specialized contract manufacturing for stick packs, providing packaging services in various sizes. They accommodate diverse products such as beverage mixes, sweeteners, and dissolving nutritional powders. Serving the nutrition and food industries, Brand Nutra delivers efficient, customized stick pack solutions tailored to client specifications for various product formulations.

Torrance, CA

Based in Torrance, CA, Cal Pack Foods provides co-packing services for fresh foods and beverages. They offer manufacturing and packaging capabilities, including pouching, and utilize high pressure processing (HPP) to extend shelf life naturally. Cal Pack supports a range of products such as juices, smoothies, salsas, dressings, purees, and dips.

Buford, GA

Catalyst Nutraceuticals offers custom manufacturing and formulation of dietary supplements for performance nutrition and wellness brands. They specialize in high-capacity stick pack production, achieving up to 25,000 units per hour, along with powders, capsules, and gusseted bags. The company focuses on quick lead times and reliable sourcing.

Carol Stream, IL

Based in Carol Stream, IL, CP Flexible Packaging is a direct manufacturer of flexible packaging solutions. They specialize in stick packs, pouches, and rollstock, offering convenient single-serve and portable options for diverse on-the-go consumer products. The company operates multiple US manufacturing facilities.

Based in Milford, PA, Econo-Pak is a contract food packaging and co-manufacturing provider specializing in custom dry powder filling services. They offer high-volume solutions for wrapping, pouching (including stick packs), bagging, and cartoning. The company also provides display, labeling, and full-service kitting, adhering to rigorous standards like SQF Level 3, FDA compliance, and organic/gluten-free certifications.

Mission Viejo, CA

Based in Mission Viejo, CA, EliteFill, Inc. offers custom packaging, filling, and formulation services, specializing in stick packs. They cater to cosmetics, nutritional supplements, and other consumer packaged goods sectors. Their products are 100% made in the USA, and clients retain ownership of their proprietary formulations.

Ontario, CA

Based in Ontario, CA, Everest Formulations is a contract manufacturer for cosmetic, food, nutraceutical, and personal care industries. They provide custom solutions for single-serve and multi-serving packaging formats, managing in-house formulation, components, and labels. Their services include refining formulas to meet specific flavor and performance standards.

Santa Fe Springs, CA

Fortis Solutions Group, based in Santa Fe Springs, CA, specializes in creating outstanding packaging solutions for diverse markets. They offer flexible packaging, including solutions for stick packs, alongside pressure-sensitive labels, shrink sleeves, and folding cartons. The company emphasizes industry-leading lead times and quality control.

La Crosse, WI

Based in La Crosse, WI, Inland Packaging manufactures high-performance labels and flexible packaging solutions. They offer a range of formats, including stand-up and flat pouches, sachets, rollstock film, and stick packs, designed to help brands differentiate and drive sales.

Tracy, CA

Based in Tracy, CA, Koru Pacific Packaging provides custom co-packaging, co-manufacturing, and toll blending services. They specialize in packaging powders, capsules, and tablets for companies of all sizes, from startups to global manufacturers. The company emphasizes exceptional customer service and total quality assurance.

Maco PKG is a contract packaging and flexible packaging company specializing in co-packing, liquid and dry filling, and customized solutions. They offer bags and pouches for diverse industries such as food & beverage, nutraceutical, and pharmaceutical markets. Maco PKG is ISO 9001:2015 and SQF Level 3 certified.

Portage, IN

Based in Portage, IN, MSI Express is a contract manufacturing and packaging company, identifying stick packs as a center of excellence. They offer blending and packaging for dry foods, liquids, vitamins, supplements, and pet food. The company operates FDA registered and SQF-certified facilities.

NutraSeller is a GMP-certified and FDA-registered contract manufacturer specializing in stick pack production for nutraceutical supplements. Their facility ensures high-quality manufacturing through strict environmental controls and advanced dust collection systems. The company offers comprehensive supplement services, prioritizing rigorous quality control, transparency, and competitive pricing.

Santa Ana, CA

Based in Santa Ana, CA, Pack Your Foods offers turn-key food manufacturing and flexible packaging services. They specialize in private label and new food development, handling formulation through go-to-market for dry, powder, liquid, and paste products. Their packaging capabilities include stick packs, sachets, and other flexible formats.

Westwood, NJ

Based in Westwood, NJ, Sonic Packaging provides innovative packaging solutions, specializing in stickpacks. These cylindrical, unit-dose packages are ideal for powders, liquids, and gels. The company helps clients streamline their entire packaging process, from initial concept to final market delivery.

Montebello, CA

Based in Montebello, CA, Sunshine FPC manufactures flexible food packaging. The company provides a range of printed films, pouches, and bags, specializing in compostable and biodegradable green packaging materials. They have over 20 years of experience serving the food packaging industry.

Euless, TX

Tejas, based in Euless, TX, manufactures flexible packaging primarily for the nutraceutical industry. They produce reliable pouches, high-performance films, and specialty bags. The company focuses on improving product visual appeal and market speed, integrating sustainable practices into its custom packaging solutions.

Laurel, NJ

The M. Company specializes in stick pack co-packing services, noted as one of the first co-packers in the United States. They provide comprehensive capabilities, equipment, and capacity designed to meet various stick-pack manufacturing needs for their clientele.

Cedar Grove, NJ

Based in Cedar Grove, NJ, Unit Pack provides unit dose contract packaging solutions for liquid-filled single-use products. They specialize in custom sachets and pouches for liquids, creams, gels, and oils. Serving cosmetics, pharmaceuticals, and industrial sectors, their FDA-registered facility offers retail, single-dose, and sample packaging.

Duarte, CA

Based in Duarte, CA, We Pack It All offers contract filling and co-packaging services, specializing in stick packs, sachets, bottles, and pouches. Serving health and wellness brands, CPG suppliers, and retailers, they provide comprehensive primary and secondary packaging solutions to accelerate business growth for clients.

Chicago, IL

Amcor is a prominent global packaging manufacturer providing a diverse range of flexible and rigid packaging solutions, including specialized stick packs. They offer innovative single-serve stick pack solutions with easy-open systems, serving various industries. Amcor operates numerous manufacturing facilities across the United States.

Evansville, IN

AmeriQual is a US-based contract manufacturer specializing in shelf-stable food processing and packaging. They offer expertise in flexible and semi-rigid packaging, including manufacturing stick pack products for powders, liquids, and gels. The company provides co-packing services for various food and beverage applications.

Baldwin Richardson Foods Co. provides custom packaging manufacturing capabilities for food and beverage products. They offer tailored solutions for industrial and ready-to-drink items, including aseptic beverages, syrups, fillings, sauces, and dessert toppings. The company specializes in co-packing services, utilizing its own facilities for diverse packaging formats.

Addison, IL

Based in Addison, IL, Omni Packaging Solutions specializes in contract packaging and fulfillment. They offer comprehensive manufacturing solutions, including stick packs, sachets, pouches, and flow wrap. The company provides versatile, high-quality packaging for single-serve products, powders, and liquids, serving various industries with advanced technology.

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How to Choose a Company

  • Verify their experience and equipment (e.g., auger fillers, volumetric fillers) in handling your specific product's flow characteristics (e.g., free-flowing powder, hygroscopic granules, high-viscosity liquid) to ensure consistent fill accuracy within target weight/volume ranges. Ask for their standard deviation limits on fill weights for similar products.
  • Scrutinize their expertise in multi-layer film selection and sealing technology. Confirm they can provide robust Fin Seal integrity testing and recommend appropriate barrier films (e.g., oxygen, moisture, UV barriers) critical for maintaining your product's stability and shelf life, especially for sensitive ingredients like probiotics or active botanicals.
  • For ingestible products, demand proof of current FDA registration and cGMP compliance, evidenced by recent audit reports. For specific markets, inquire about USDA Organic, NSF (especially NSF Sport), Kosher, Halal, or Child-Resistant Packaging (CRP) testing capabilities relevant to your product's claims and regulatory requirements.
  • Distinguish between suppliers set up for enterprise-level, high-volume production (often with multi-lane Form-Fill-Seal machines and high MOQs) and those catering to startups or niche brands with lower MOQs and more flexible scheduling. Understand their lead times for both initial runs and reorders, as these can vary drastically.
  • Red Flag: Be wary of manufacturers who don't ask detailed questions about your product's specific properties (density, particle size, pH, viscosity) or gloss over the critical importance of film barrier properties. A lack of specific questions about your formulation or an inability to explain their Fin Seal validation process often indicates a potential for future quality issues or stability compromises.

Frequently Asked Questions

What's the key difference between a stick pack and a sachet, and does it impact manufacturing?

While both are flexible pouches, a stick pack is typically a narrow, elongated pouch with seals along its top, bottom, and a single vertical "fin seal" on the back. A sachet is usually wider and flatter with four seals – top, bottom, and two side seals. This distinction significantly impacts manufacturing: stick packs are typically made on multi-lane vertical form-fill-seal (VFFS) machines, often achieving higher speeds and specific dimensions for single-serve "on-the-go" consumption. Sachets, conversely, might use horizontal FFS (HFFS) or VFFS, offering different size and shape flexibilities. The fin seal design of stick packs can also influence film material choices and sealing integrity challenges.

What minimum order quantities (MOQs) should I expect for stick pack production?

MOQs for stick packs vary widely based on the manufacturer's equipment, your product type, and packaging complexity. For liquid or powder stick packs, startups often face MOQs ranging from 50,000 to 250,000 units, sometimes even higher. This accounts for setup costs, film minimums, and efficient utilization of multi-lane Form-Fill-Seal (FFS) machinery. Some specialized boutique co-packers might offer lower MOQs (e.g., 25,000 units) for a premium, but it's crucial to clarify all associated setup fees and tooling costs beyond the per-unit price.

How critical are barrier films for stick packs, and what should I ask manufacturers about them?

Barrier films are extremely critical for stick packs, especially for products sensitive to moisture, oxygen, light, or aroma loss (e.g., vitamins, instant coffee, probiotics, delicate flavorings). You should ask manufacturers about their expertise in multi-layer film structures (e.g., PET/Foil/PE, OPP/MET-OPP/PE) and their ability to recommend specific barrier properties (e.g., WVTR - Water Vapor Transmission Rate, OTR - Oxygen Transmission Rate) suitable for your product's shelf-life requirements. Also inquire about their material lead times, as specialized films often have longer procurement cycles.

What specific challenges do highly hygroscopic powders or high-viscosity liquids present in stick pack filling?

Highly hygroscopic powders (those that absorb moisture easily) pose significant challenges due to their tendency to clump, bridge, or stick to machinery, impacting fill accuracy and potentially jamming production lines. Manufacturers need specialized auger fillers with agitators, controlled humidity environments, and specific anti-static films. High-viscosity liquids (like gels, pastes, or thick creams) require specific pump systems, wider orifices, heated hoppers, and often slower line speeds to ensure accurate and consistent filling without stringing or dripping. Always discuss these product-specific characteristics in detail to ensure the manufacturer has appropriate equipment and experience.

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