Want eco-friendly stick packs? Here’s what’s real, what’s hype, and what your brand needs to know about barrier protection, PCR film, and sustainability that actually scales
If you’re launching a powder or liquid supplement brand, you feel the pressure.
Consumers want sustainable packaging. Retailers expect it. And as a founder, you probably do too.
But the truth about sustainable stick packs? It’s more nuanced than most blogs or sales pages are willing to admit.
At Steuart Nutrition, we’ve been through it all: trends that took off overnight, others that flamed out fast, and countless “eco-friendly” ideas that sounded great until they met reality on the production floor.
Let’s talk about what actually works in sustainability. No greenwashing, just hard-won lessons from the line.
As we built the business over the last seven years, we learned that materials matter. During the Covid-19 crisis, entire markets swung overnight, bottles ran out, packaging disappeared, and suddenly every supplier was offering an “alternative” solution.
That season taught us something we’ve carried ever since: adaptability is KEY.
The same is true with sustainable packaging. Here’s where we’ve seen CPG founders get tripped up…
Sometimes, they jump on the latest compostable film or laminate. It sounded good on paper, why not? But then two months later, their electrolyte powder clumps, seals fail, or the pouches delaminate.
We’ve tested plenty of these. But they’re a liability in real-world logistics. They just aren’t shelf-stable.
Then there are MOQ issues for custom packaging supplies. Eco-film suppliers may require 50k+ impressions, so be ready to batch or split across flavors.
The good news? A solid manufacturer won’t just sell you what’s easiest for them. They’ll guide you through the process from start to finish.
Most stick packs are made from laminated rollstock – a layered film that’s engineered to keep moisture, oxygen, and light from degrading your product.
And that “eco-friendly compostable film” that sounds amazing on the sales page? It lets in too much moisture, and it’s going to turn your electrolyte powder into a rock in a couple weeks.
That’s why most stick pack films aren’t biodegradable. Because they can’t be (at least, not yet). Not if you want the product to stay functional, mixable, and shelf-stable.
If you’re looking for sustainable packaging that doesn’t compromise performance, post-consumer recycled (PCR) film is the most practical option.
It blends a percentage of recycled plastic into the film, often between 25% and 50%, without sacrificing the barrier you need to protect shelf life.
Our trusted partners: Bellmark, Amcor, ePac, EcoPackables, Fortis, and CP Flexible are all offering PCR films that can run cleanly on high-speed stick pack lines.
With them, you get:
Even if the film itself isn’t compostable, stick packs drastically reduce plastic waste compared to alternatives like bottles or tubs.
Let’s do the math:
Not to mention, you’re not shipping water across the country.
Since water is added by the customer, stick packs cut down on the fuel, weight, and energy needed to distribute your product.
We’re in the camp of doing what actually works, not just what sounds good in a marketing deck.
If it’s not good for the product, customer, or business? It’s not a sustainable solution.
That starts with reducing the overall plastic footprint with single-serve powder formats, using PCR film where it makes sense, making sure packaging protects your product without killing margins, and helping you tell a sustainability that’s authentic, not performative.
If you were launching a hydration brand targeting Gen Z, a group that’s deeply aware of sustainability and their environmental impact, here’s what we’d recommend.
Instead of using expensive recycled plastic bottles or chasing the dream of a fully compostable film, try this: launch with a stick pack that eliminates over 90% of packaging waste compared to bottled alternatives.
It won’t kill your margins, and it’s still more sustainable than the alternative. Plus, it would provide your customers a better experience. Students could toss the sticks in their backpacks, mix them later in a water bottle, and avoid a trip to the gas station or vending machine. That kind of portability and convenience aligns perfectly with a Gen Z target audience.
On top of all that:
We’ll walk you through real-world options, film specs, and how to launch something that’s sustainable (and still works on every level).
Book a discovery call, and let’s build smart from the start.
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.
Your Brand Deserves a Manufacturing Partner That Scales With You.