Stick Pack Manufacturing For Powders

Stick Pack Powder Products We Manufacture

We manufacture all supplement-grade powder formulations into single-serve stick packs, allowing full customization for private label brands. Our specialized stick pack production facility is designed specifically for precise dosing and hermetic sealing that preserves potency and extends shelf life.

Types of Stick Pack Powder Supplements Available

• Electrolyte Powders – Hydration & recovery blends with precise mineral ratios
• Pre-Workout Powders – Energy & endurance formulations requiring exact dosing
• Collagen & Protein Powders – Beauty & muscle recovery support in convenient portions
• BCAA & EAA Powders – Muscle-building and recovery blends with precise amino ratios
• Superfood & Greens Powders – Immunity-boosting and detox formulas with superior mixability
• Instant Coffee & Adaptogen Blends – Cognitive support and relaxation powders for on-the-go
• Keto & Fasting Support Powders – MCT oil, exogenous ketones, and metabolism boosters
• Sleep & Relaxation Powders – Melatonin, magnesium, and herbal blends for evening use

Stick Pack Engineering Advantages

• Multi-Layer Barrier Films – Custom moisture, oxygen, and light protection
• Precision Filling Technology – Accurate dosing within 0.1g tolerances
• Proprietary Sealing Systems – Prevents leakage and contamination
• Custom Tear Notches – Designed for easy opening without spillage
• Specialized Powder Flow Agents – Ensures complete emptying of stick pack contents

Popular Powder Stick Pack Formulations

• Electrolyte Hydration Mix – Sodium, potassium, and magnesium for fast rehydration
• Protein Powder Stick Packs – Whey, plant-based, or collagen protein blends
• Prebiotic + Probiotic Powder – Gut health and digestion support
• Nootropic Brain Boost Powder – Caffeine + L-theanine + Lion’s Mane for focus
• Immune Support Vitamin C & Zinc – Antioxidant and immunity boost
• Fat Burner & Thermogenic Powder – Green tea, L-carnitine, and CLA blend

Stick Pack Design Options

• Size Customization – From 2g mini-sticks to 25g protein-sized formats
• Film Selection – Metallized, clear, or custom colors and finishes
• Custom Printing – Up to 8-color printing with matte or gloss options
• Eco-Friendly Options – Biodegradable and recyclable film alternatives
• Perforation Systems – Multi-pack designs with easy separation features

Custom Flavor Options for Stick Pack Powders

• Mixed Berry
• Lemon Lime
• Chocolate Mocha
• Tropical Mango
• Vanilla Bean
• Matcha Green Tea
• Unflavored
• Blue Raspberry
• Watermelon
• Strawberry Kiwi
• Lemonade
• Orange Cream

Stick Pack Packaging Solutions

• Individual Stick Packs – Perfect for sampling and on-the-go use
• Multi-Pack Boxes – Retail-ready packaging with custom branding
• Dispenser Cartons – Convenient storage and dispensing systems
• Point-of-Sale Displays – Counter and shelf merchandising options
• Variety Pack Assortments – Multiple flavors in convenient multi-packs

Our comprehensive stick pack manufacturing capabilities allow your brand to create convenient, precise, and portable powder supplement solutions that meet today’s consumer demands for on-the-go nutrition.

Step-by-Step Stick Pack Manufacturing Process

1. Consultation & Custom Formulation

Work with NutraSeller’s R&D team to develop a unique stick pack formula. Our powder specialists analyze flow characteristics, particle size uniformity, and dissolution properties to ensure optimal performance in stick pack delivery. We determine ideal excipient ratios that prevent clumping and ensure complete emptying of each packet, while our flavor chemists develop systems specifically engineered for single-serve consumption.

2. Ingredient Sourcing & Blending

We source premium ingredients with verified certificates of analysis, focusing on powder properties essential for stick pack performance. Our specialized blending technology ensures homogeneous distribution of active ingredients, preventing settling or separation within the stick pack. Each powder blend undergoes rheological testing to verify flow characteristics and filling consistency before proceeding to the packaging phase.

3. Precision Stick Pack Filling & Sealing

Your powders enter our dedicated stick pack production suite featuring state-of-the-art vertical form-fill-seal (VFFS) machinery. Our specialized auger filling systems achieve dosing accuracy within 0.1g tolerances, while advanced multi-zone sealing technology creates hermetic closures that prevent moisture ingress. We utilize specially designed film structures with multiple barrier layers that protect sensitive ingredients from oxygen, light, and humidity.

4. Third-Party Testing & Quality Control

Each production batch undergoes comprehensive quality verification including weight consistency checks, seal integrity testing, and barrier property validation. Our multi-point inspection system examines every stick pack for proper fill levels, seal quality, and print alignment. We conduct stability challenge testing under accelerated conditions to verify shelf life performance and powder integrity throughout the product lifecycle.

5. Private Label Branding & Packaging

Our graphics team works closely with your brand to develop custom stick pack designs that maximize visual impact while meeting regulatory requirements. We offer up to 8-color printing with specialty finishes including matte, gloss, and metallized effects. Your stick packs can be packaged in custom retail boxes, dispensing cartons, or bulk configurations based on your distribution strategy.

6. Bulk Order Fulfillment & Shipping

We implement specialized handling protocols for stick pack products, including climate-controlled storage and cushioned packaging that prevents damage during transit. Our logistics team coordinates efficient delivery options from small sample batches to full container loads. For international orders, we provide complete documentation to facilitate smooth customs clearance for dietary supplement products.

Compliance & Quality Assurance

GMP-Certified & FDA-Registered Facility

Our stick pack production facility maintains strict environmental controls with specialized dust collection systems and cleanroom-grade air filtration. We implement comprehensive validation protocols for each new stick pack product, ensuring consistent quality from first production run to large-scale manufacturing.

Third-Party Testing

Each powder batch undergoes full analytical verification including potency testing, microbial screening, and contaminant analysis before packaging. Our finished stick packs receive additional verification including moisture analysis, oxygen permeation testing, and accelerated stability studies to confirm packaging performance.

Organic Certifications Available

We maintain multiple certifications to support your marketing needs, including FDA registration,  GMP certification, and various specialized approvals for organic, non-GMO, and allergen-free products.

Labeling & Compliance Support

Our regulatory experts ensure your stick pack labeling meets all FDA requirements, including appropriate structure/function claims and ingredient disclosures specifically formatted for the unique space constraints of single-serve packaging.

Packaging & Customization Options

Stick Pack Private Label Packaging Formats:

• Standard Stick Packs – 3-7g single-serve powder packaging with precision filling technology ensuring exact dosage delivery. Our standard formats feature quad-seal construction with superior barrier properties against moisture, oxygen, and light—essential for preserving sensitive supplement ingredients.
• Custom Stick Pack Sizes – 5g, 10g, 15g, or other customized weights designed for specific product requirements. We offer specialized dimensions from mini-sticks for concentrated formulas to larger formats for protein powders, with customized width-to-length ratios that optimize both filling efficiency and consumer experience.
• Multipack Stick Pack Boxes – 7-day, 14-day, or 30-day supply options with retail-ready packaging. Our custom carton designs include specialized dispensing features, tamper-evident seals, and shelf-stabilizing designs that maximize product presentation while protecting stick pack integrity during shipping and display.
• Eco-Friendly Stick Pack Materials – Compostable & biodegradable options that align with sustainability-focused brand positioning. We offer plant-based films, reduced-plastic structures, and recyclable alternatives while maintaining the critical barrier properties necessary for supplement preservation.

Stick Pack Design Elements:

• Film Structure Selection – Customized barrier properties based on your product’s specific sensitivity profile
• Specialized Tear Notches – Engineered for single-handed opening without powder spillage
• Custom Printing – Up to 8-color process with specialty finishes including matte, gloss, and metallic effects
• Perforation Systems – Multi-pack configurations with easy-separation features
• Coding & Batch Information – Laser-etched lot codes and expiration dating for quality tracking

Customization Options:

• Organic & Vegan Powder Formulations – Clean-label formulations specifically engineered for stick pack delivery. Our powder specialists ensure proper flow characteristics and dissolution properties while maintaining organic certification and vegan compliance.
• Natural Sweeteners – Zero-calorie and clean-label sweetening systems optimized for single-serve formats. Our stick pack flavor scientists have developed precise monk fruit, stevia, and erythritol ratios that deliver consistent sweetness in small-volume applications where traditional sweeteners often perform unpredictably.
• Functional Blends with Superfoods, Probiotics & Adaptogens – Specialized formulations combining multiple active ingredients in precisely measured single-serve doses. Our stick pack technology ensures even distribution of multiple ingredients with different particle sizes and densities, preventing separation issues common in complex powder blends.

Specialized Stick Pack Innovations:

• Grip-Texture Surfaces – Specialized film embossing for easy handling
• Tear-Direction Indicators – Visual cues for proper opening technique
• QR Code Integration – Links to preparation videos and usage instructions
• Serialization Capabilities – Individual tracking codes for marketing promotions

Our stick pack engineers work closely with your team to develop single-serve packaging that maximizes convenience, extends shelf life, and creates a premium user experience that builds brand loyalty in today’s competitive supplement marketplace.