What Stick Pack Size Should I Use for My Product?

At Steuart Nutrition, we get this question all the time:

“What stick pack size should I use for my product?”

If you're launching a powder supplement or hydration product, choosing the right stick pack size is more than a design choice—it’s a decision that impacts functionality, cost, consumer experience, and even shelf presence.

Here’s what you need to know.

There’s No One-Size-Fits-All Stick Pack

The stick pack you choose depends on three critical factors:

1. Your Formula’s Fill Weight

Denser products like collagen or creatine require more volume. A hydration powder might be fine in a 23mm stick, but that same size could be cramped—or even unusable—for heavier formulas.

💡From our experience: When we first launched Steuart Nutrition, one of our first equipment purchases was a small two-lane stick pack machine. It helped us get off the ground, but only supported a narrow range of sizes. That experience taught us that limiting stick pack sizes can be detrimental to a brand’s success, and one of the reasons we’ve invested in more flexible options down the road.

2. How the Consumer Uses It

• On-the-go hydration? Slim, tall sticks (23–26mm) work well.
• At-home wellness ritual? Wider sticks (30–41mm) feel more premium and stand out on a shelf.

Mixing with less water? You might want a shorter stick to communicate smaller servings.

3. Your Brand Positioning

If you want to differentiate, your packaging needs to do some heavy lifting. Stick packs aren’t just functional—they’re part of your marketing. A larger 41mm stick can make a bold statement. A sleek 26mm format communicates precision and portability.

💡From our experience: We once worked with a supplement brand that wanted to differentiate themselves with a bunch of exotic flavors. It sounded exciting, but the truth is, most consumers gravitate toward flavors—like chocolate or vanilla—they’re already familiar with.

As an alternative, we advised cutting back on the number of flavors, but differentiating themselves with packaging design and size. Their offerings popped on the shelves, and we’ve been filling orders for them ever since.

The Problem: Most Manufacturers Limit Your Options

Here’s the issue: most stick pack manufacturers can only run one or two sizes. Why? Because their machines were tooled for the standard from 5-10 years ago. Most were 23mm because they were designed to go with a disposable water bottle.

But in the early 2010s, consumers moved away from single-use plastic bottles, brands wanted to differentiate themselves, and larger size stick packs became more popular.

However, even if they have more than one size, changeovers are expensive, slow, and complex. That limits your flexibility and forces you to conform your product to their equipment.

That’s not how we work.

At Steuart Nutrition, You’re Not Stuck with One Size

We built our entire stick pack operation around flexibility and speed. Our American-made RoPack machines allow us to:

• Run any stick pack size from slim to wide (23mm–41mm and beyond)
• Perform fast tooling changeovers in minutes—not hours or days
• Give you the freedom to choose the stick that fits your brand, not the other way around

👉 Explore our stick pack capabilities

Whether you want to mirror what’s already working in your category—or launch a size that breaks the mold—we help you make that call based on data, experience, and what’s best for your product and your market.

Still Not Sure What Size Is Right?

Let’s walk through it together.

At Steuart Nutrition, we work with brands at every stage—from first product launches to high-growth scale-ups. We help you consider fill weight, serving size, mixing behavior, and branding goals so you can choose a stick pack size that’s right the first time.

📦 Get a quote today, and we’ll guide you through the sizing and packaging strategy from start to scale.

Ben Steuart — CEO & Owner, Steuart Nutrition

Ben Steuart is the co-founder and CEO of Steuart Nutrition, a contract manufacturing and supplement innovation partner for powder, liquid, and stick‑pack supplements. He launched the company in 2019 alongside his wife, Sarah, building on his lifelong roots in the food production industry, where he grew up working in his father's food-manufacturing business in Mabel, Minnesota.

Throughout his career, Ben has developed deep expertise in supplement manufacturing and business operations. At Steuart, he leads with a commitment to lean operations, fostering long-term partnerships, and delivering flexible, transparent service—prioritizing the client’s vision as much as his own. His leadership guided the business’s rapid expansion from a single facility to multiple locations, enabling agile responses to market needs—from producing hand sanitizer during the COVID‑19 pandemic to scaling CBD and nutrition supplement lines.

Ben’s approach is rooted in strong values—his faith as a born‑again Christian deeply informs the company’s mission of “glorifying God and establishing a transformational workplace”. This culture of integrity and continuous improvement fosters a trusting, mission-driven environment, distinguishing Steuart as both a capable and conscientious industry leader.