Flexible Food Manufacturing

Stick Pack vs. Sachet Packaging: What Packaging Design Is Best for Manufacturing?

October 6, 2025

If you’ve ever torn open a packet of instant coffee, powdered drink mix, or condiments, you’ve used either a stick pack or a sachet. While these two packaging formats may seem similar at first glance, they are designed for different purposes, and understanding the differences can help you choose the best option for your product.

For food, beverage, and supplement brands, especially those dealing with powdered or single-serve products, selecting the right packaging format affects product appeal, production efficiency, and profitability. In this guide, we’ll break down the key distinctions between stick packs and sachets, their pros and cons, and how to decide which is best for your manufacturing business.

What Is a Stick Pack?

A stick pack is a narrow, tube-shaped packet designed for single servings. Typically measuring 0.5 to 1.5 inches wide and 2 to 6 inches long, stick packs are made from laminated film and sealed on three sides to protect the product from moisture, oxygen, and light.

They are popular in the food, beverage, and supplement industries for products like:

  • Electrolyte and hydration powders
  • Instant coffee and tea
  • Protein powders and collagen supplements
  • Single-serve sweeteners
  • Spices and seasoning blends

Stick packs are usually produced using multi-lane vertical form-fill-seal (VFFS) machines, which can run at high speeds to produce thousands of units per hour.

What Is a Sachet?

A sachet is a small, flat packet, often square or rectangular, sealed on all four sides. They can be filled with powders, liquids, granules, or gels, making them highly versatile.

Sachets are common in:

  • Condiments like ketchup, mustard, and mayonnaise
  • Salad dressings and sauces
  • Sugar, sweeteners, and creamers
  • Instant coffee or cocoa
  • Single-use personal care products like shampoo or lotion

Sachets can be produced in various sizes, from small sample packets to larger portion-controlled packages. The packaging machinery for sachets is designed for flexibility, allowing for different fill materials and viscosities.

Key Differences Between Stick Packs and Sachets

  1. Shape and Presentation
    • Stick Pack: Slim, elongated shape designed for easy pouring into bottles or glasses.
    • Sachet: Flat, compact shape designed for portion control and easy storage.
  2. Product Compatibility
    • Stick Pack: Best suited for free-flowing powders or granules.
    • Sachet: Suitable for powders, liquids, pastes, or granules.
  3. Portion Size
    • Stick Pack: Ideal for small, single-serve doses (often 1–15 grams).
    • Sachet: Can accommodate a wider range of sizes, from 1 gram to over 50 grams, depending on the application.
  4. Consumer Use
    • Stick Pack: Easy to pour without spilling; designed for on-the-go use.
    • Sachet: Often requires tearing along a notch; can be used directly (e.g., squeezing sauce onto food) or poured into a container.
  5. Branding Surface
    • Stick Pack: Limited surface area for branding, but still allows for creative vertical designs.
    • Sachet: Larger flat panels offer more space for graphics, nutrition labels, and branding.

Advantages of Stick Packs

  1. Portability and Convenience
    Slim enough to slip into a pocket, purse, or gym bag. Perfect for active, on-the-go consumers.
  2. Accurate Dosing
    Each stick pack contains a pre-measured amount, eliminating the need for scoops or measuring spoons.
  3. Reduced Packaging Waste
    Compared to jars or tubs, stick packs use less material per serving, helping brands align with sustainability goals.
  4. Shelf Appeal
    Stick packs can be displayed in branded cartons or countertop dispensers, enhancing retail presence.

According to industry reports, the global stick packaging market was valued at over $460 million in 2023, and is projected to grow to over $650 million by 2030. This is due to rising demand for portion-controlled and portable formats.

Advantages of Sachets

  1. Versatility
    Sachets can hold powders, liquids, or semi-liquids, making them a go-to for both food and personal care products.
  2. Larger Fill Options
    With more size flexibility, sachets can serve as both single-serve and multi-portion packages.
  3. More Branding Space
    The larger flat panels give more room for messaging, regulatory information, and eye-catching design.
  4. High Production Efficiency
    Multi-lane sachet machines can produce large volumes in a variety of shapes and sizes.

The global sachet packaging market is significantly larger than stick packaging, valued at over $9.8 billion in 2024, and is expected to grow at a CAGR of 5.5 % from now until 2030.

Cost Considerations

Stick Packs:

  • Pros: Lower material use per unit, high-speed production, low freight costs due to small size.
  • Cons: Requires specialized machinery, limited surface area for branding, primarily suited for powders.

Sachets:

  • Pros: Can package more product types, more branding space, flexible size options.
  • Cons: Often uses more packaging material per unit, and larger format may increase shipping costs.

When evaluating costs, consider not only the material and production expenses, but also shipping, storage, and shelf presentation. A smaller, lighter stick pack may save significantly on logistics, while a sachet might deliver better brand visibility and versatility.

Sustainability Considerations

Both stick packs and sachets typically use laminated films, which can be challenging to recycle due to multi-layer construction. However, the smaller material footprint of stick packs can reduce overall environmental impact. For brands prioritizing sustainability, advances in recyclable and compostable films are expanding options for both formats.

A recent survey found that 60-70% of U.S. consumers are willing to pay more for sustainable packaging, a clear signal that eco-friendly material choices can be a competitive advantage.

Choosing the Right Option for Your Brand

The decision between stick pack and sachet packaging depends on several factors:

  1. Product Type – Is it a powder, liquid, or paste? Stick packs are great for free-flowing powders, while sachets handle a wider range of consistencies.
  2. Serving Size – Stick packs shine for small, single-serve doses; sachets are better for larger portions or diverse product types.
  3. Consumer Use Case – Will customers pour it into a container, add it to a beverage, or use it directly from the package?
  4. Branding Needs – If you require more labeling space for regulations, instructions, or marketing, sachets may be better.
  5. Distribution Channels – If you’re selling primarily in gyms, convenience stores, or e-commerce kits, portability and reduced shipping costs may make stick packs more appealing.
  6. Budget and Equipment – Stick pack filling requires specific machinery; if your co-packer doesn’t have it, sachets may be more cost-effective to start.

    Your Perfect Packing Partner

    While stick packs and sachets serve similar purposes, they are far from interchangeable. Each format has strengths that align with different products, consumer expectations, and brand strategies.

    • Choose stick packs when portability, small doses, and lightweight shipping are top priorities.
    • Choose sachets when versatility, larger serving sizes, and more branding space matter most.

    At National Packaging, we work with brands to determine the best packaging solutions for their unique products. Whether you’re leaning toward stick packs, sachets, or a combination of both, our team can guide you through the decision-making process, from design and material selection to production and distribution.

    Get in touch with our team today to explore your options!