Stick Packs: Frequently Asked Questions

Hey there. I’m Ben Steuart, founder and CEO of Steuart Nutrition, and here are the most common questions we get from founders looking to launch a stick pack product.

1. What Is the Minimum Order Quantity (MOQ) for Stick Pack Manufacturing?

Most high-speed multi-lane machines require an MOQ between 100,000 and 150,000 sticks. This equipment is efficient for large-scale production, but may not be cost-effective for smaller runs.

We also have single-lane machines that can handle MOQs as low as 20,000 units for the right brand.

Whether or not you decide to work with us, it’s crucial to know if your chosen manufacturer can scale with your brand’s growth. Many stick pack manufacturers specialize in either small or large runs, but often can’t handle both. That means as demand increases for your product, you may outgrow your manufacturer and have to go through a painful transition 

For more information, read our Navigating MOQs guide.

2. What’s the Cost Per Unit for Stick Packs?

Determining costs can be tricky, especially at low volumes. To be sure about a quote, you have to contact your manufacturer. But in general, orders under 50,000 units range from $0.15 to $0.50 per stick pack.

Ranges account for various factors, including:

• Product characteristics: Flowability and density can impact packaging efficiency and costs.
  
• Packaging materials: Film quality and type influence price.
  
• Printing and design: Custom designs or multiple color prints may increase costs.
  
• Order size and frequency: Larger or more frequent orders can come with volume discounts.

It’s important to note that these are general estimates. For a more accurate stick pack manufacturing quote, please reach out to us for a free consultation.

3. What Materials Are Used in Stick Pack Packaging?

Packaging comes in all shapes and sizes, each offers distinct benefits. Selecting the appropriate material depends on your unique requirements and brand values.

• Easy-tear films: Designed for customer convenience, these films allow for effortless opening without compromising the package’s integrity.
  
• High-barrier films: Multilayer films provide excellent protection against moisture, oxygen, and light, ensuring freshness for extended shelf lives.
  
• Eco-friendly films: Some manufacturers offer recyclable or compostable films, catering to environmentally conscious brands. Read more in our truth about stick pack sustainability article. 

4. How Do I Choose the Right Stick Pack Size?

Size is vital for both functionality and brand presentation. Common widths include:

• 23mm: Ideal for lightweight drink mixes or electrolytes.
  
• 26mm: Offers a slightly wider footprint for a more substantial feel.
  
• 30mm: Provides a balance between capacity and portability.
  
• 35mm: Suitable for products with large volume fills.
  
• 41mm: Best for bulkier powders or higher dosage products.

To decide which size is best for you, ask yourself what your fill weight is, how you want the product to feel in a customer’s hands, and which sizes scale well for retail, e-commerce, and copacking. 

For detailed information, read our article on how to choose the right stick pack size.

5. What’s a Typical Lead Time for Stick Pack Production?

Lead times range from a few weeks to a couple months.

They can vary based on:

• Film printing: Custom films may require additional time for design and production testing.
  
• Blending and testing: Ensuring quality and consistency, especially for new products, takes time.
  
• Line capacity: Our current workload and machine availability can influence lead times.

To expedite the process, we recommend engaging early with your manufacturer to align on timelines, keeping commonly used materials in stock, and being adaptable with timelines to accommodate unforeseen delays. 

Who Is Steuart Nutrition?

Most manufacturing is done around bigger cities, but we’re in rural Minnesota.

And we hear this a lot when people visit our facility. 

“Wow, I wasn’t expecting THIS out here.”

We’re building world-class systems in our small town-zip code. It’s surprising to some people.

Step into any of our facilities, and you’ll find:

• The best equipment
  
• Extremely detailed processes
  
• Vigilant quality control and testing
  
• And most importantly, passionate people who actually care

We handle stick pack manufacturing projects from initial concept to full-scale production. No handoffs, no confusion, just one team that owns your results. 

And we’ve got the happy clients to prove it. Here’s what Tyler Dooley, CEO of Wake Up Water, has to say about working with us:

“As a small but fast-growing CPG brand, finding the right manufacturing partner was critical. Before Steuart, we dealt with the usual challenges: high minimum order quantities, inconsistent quality, and poor communication. Partnering with Steuart changed everything. They offered smaller production runs at competitive prices and prioritized clear, responsive communication. I feel like I can call, text, or email them at any time with any issue. With their support, we’ve been able to focus more on growing our business and less on production worries. Steuart has been a key part of our success, and we’re excited to continue growing together.”

— Tyler Dooley, CEO of Wake Up Water

Your Next Move

When the time is right, book a discovery call. We’ll walk you through your formula, packaging needs, costs, send samples, and provide a no-pressure roadmap developed by a stick pack manufacturing team that’s been there.