Stick pack co-packing: 1 g fills, 20–50 mm sticks, small runs welcome. Arriving Dec 2026
Our stick pack machine arrives in December 2026. It runs 30, 40 and 50 mm sticks, plus a 20 mm format built for 1 g fills that most co-packers won't touch. We're booking production windows now.
Quick answer: North Lakes Copacking will run stick packs from December 2026 in 30, 40 and 50 mm widths, plus 20 mm for 1 g fills. Pricing is $2,750 flat up to 5,000 sticks, then $0.30 a stick to 25,000 and $0.22 to 50,000; fills over 10 g add $0.03 a stick. Blending is extra. Tell us your fill weight and timeline and we'll hold you a production window.
What stick pack sizes will you run?
| Stick width | Typical use |
|---|---|
| 20 mm | 1 g fills: sweeteners, flavor boosters, sample and trial doses |
| 30 mm | Small single serves: electrolytes, energy, sugar-free drink mixes |
| 40 mm | Mid-size serves: hydration mixes, greens, collagen |
| 50 mm | Larger serves: protein shots, creatine, meal and drink mixes |
Fill weight per stick depends on your powder's bulk density and the stick length. Send your fill weight and a sample, and we'll tell you which width fits.
Why are 1 g stick packs hard to fill?
Because the legal margin is tiny. Under NIST Handbook 133, a 1 g pack can't come in under 0.9 g, and the lot average has to hit 1 g. A 0.05 g swing is 5% of the fill. We run small fills at label +3–5% and check them on a 0.001–0.01 g lab balance about every 15–30 minutes, not just a checkweigher. More in our net contents guide.
Stick packs or sachets?
Stick packs use less film per serve, pour cleanly into a bottle and look premium in a box. Sachets hold larger fills and cost less to tool for. If you're deciding, read sachet vs. stick pack, or run a sample of each.
How do I reserve a stick pack production window?
- Request a quote with your product, fill weight, units per flavor and target date.
- We confirm the stick width and send a written quote.
- Order roll stock to our film spec. Film is usually the longest lead time, so start it early. See film sizing timelines.
- Sign the quote to lock your window.
What does stick pack co-packing cost?
| Sticks in the run | Price | Example |
|---|---|---|
| Up to 5,000 | $2,750 flat | 5,000 sticks = $0.55 each |
| 5,001–25,000 | + $0.30 per stick over 5,000 | 10,000 = $4,250 ($0.43 each); 25,000 = $8,750 ($0.35 each) |
| 25,001–50,000 | + $0.22 per stick over 25,000 | 50,000 = $14,250 ($0.29 each) |
| Over 50,000 | Quoted | |
| Fills over 10 g | + $0.03 per stick | Heavier fills run slower on the stick machine |
Why sticks cost more than sachets above 5,000: our stick machine runs about half as fast as the HFFS sachet line, so the same count ties up twice the machine time. Units are counted across flavors; each extra flavor is a $250 changeover. Blending is $0.50–$1.50 per lb on top, and retail cartoning is quoted. All fees are on our pricing page.
Frequently asked questions
When can you start running stick packs?
The machine arrives in December 2026. We're booking production windows now and will confirm dates as the line is commissioned.
What is the minimum order for stick packs?
$2,750 flat covers up to 5,000 sticks, including setup and the run. Above that it's $0.30 a stick to 25,000.
Can you do a 1 gram stick pack?
Yes, on a 20 mm stick, with lab-balance sampling to hold the fill weight.
Do I need my own printed film?
Usually, yes. Printed roll stock to our film spec. We'll confirm the web width for your stick size before you order.
Related reading
- Sachet vs. Stick Pack: Which Packaging Format Is Right for Your Product?
- Electrolyte Powder Co-Packing
- How to Select Packaging Film for Powder Supplements
- Net Contents & Overfill: NIST Handbook 133 Guide for Brands
Tell us about your run.
Pricing from $2,750 flat. FDA registered. You talk to the owner.
Get a Quote →