Why Are My Stick Packs So Hard to Open?

Ever needed scissors just to open a stick pack?

Yeah. Us too. It’s infuriating. And we’ve heard the complaints: from Amazon reviews, DMs, and frustrated brand owners alike.

“Customers love the formula, but they hate opening the stick.”

“They need scissors just to get the darn thing open!”

“It’s a great product… but the packaging is turning people away.”

Nothing kills a customer/brand moment like trying to rip open your hydration powder and ending up with a powder explosion – or a jagged, half-ripped stick that feels like it was built for Fort Knox. 

So if you’ve ever had a customer complaint like that, been the customer yourself, or wanted to prevent it from happening to your products, this blog post is for you.

Why Are Some Stick Packs So Hard to Tear?

Let’s break it down. There are three core reasons your stick might not be tearing cleanly:

1. Film That’s Built Like a Fortress

Some films are just too tough. They might look sleek and premium, but without the right specs, they turn your convenient single-serve packet into a frustrating experience.

That’s because most film used in stick packs is designed for moisture protection, not openability. 

If your manufacturer chooses a stick pack film without considering user experience, you get sticks that are basically indestructible. This is why some brands unintentionally make stick packs that need scissors just to get into.

2. Poor Tear Notch Placement, or No Notch at All

A tear notch is a strategic cut that allows the consumer to start tearing the film in a controlled direction.

But too many manufacturers put the notches in the wrong spot, skip them altogether, or fail to align them with your seal pattern.

And then? Customers try harder and the stick unzips all at once. 

Total mess. Powder everywhere. Here comes the 1-star review.

3. Mismatch Between Film, Machine, and Seal Pattern

This is where it gets technical, but also where brands win or lose on packaging.

At Steuart Nutrition, we’ve seen stick pack manufacturers with machines that can only run one type of seal. They can’t offer custom tear notches. They can’t run easy-tear film. And while they may pick a film that runs well for them, it limits your options and isn’t right for your customer.

Here’s How We Fix It

When you partner with Steuart Nutrition, we don't just pick a film and hope for the best. We engineer your stick pack around usability, performance, and brand feel by:

• Matching your product with the right film, including easy-tear films, where no notch is even needed.
  

• Choosing the best seal pattern that’s both clean and tears predictably.
  
  
• Offering multiple notch types, from standard V’s to ultra-precise laser-scored lines, and perforated edges for a nice intentional rip.
  
  
• Customizing artwork, showing customers where to tear with visual cues that don’t confuse.

Don’t Let a Great Product Be Undone by Bad Packaging

Your formula might be elite. Your branding might be killer. But if the customer can’t get into the stick easily, none of it matters. 

That’s why we’re obsessed with making stick packs that don’t just perform, but also delight.

Your job is to build the brand. Our job is to make sure the packaging feels as premium as the product inside.

And if you want to give customers an Apple-level unboxing experience? Partner with a manufacturer who’s dialled this in for fast-growing brands again and again.

📞 Want a free consultation?

Talk to one of our project management pros, and we’ll walk you through the exact film and seal pattern that fits your product – and your customer. Book your call with Steuart Nutrition now.

Ben Steuart — CEO & Owner, Steuart Nutrition

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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.