What stick pack size do I need for my serving?
| Input or item | Typical value or source | Why it matters |
|---|---|---|
| Dose m | Buyer serving range, g | Sets the product mass |
| Bulk density ρ | Measured g/ml; method and sample state | Sets V = m / ρ, in ml |
| Effective flat width W | Tube drawing, mm; exclude back-seal material | Defines the ideal cross-section |
| Seal allowances | Dimensioned end seals and clearance, mm | Do not hold product volume |
| Intended use | Opening, emptying and carton brief | Limits usable dimensions |
Start with the Quick Specs inputs in this section. Use the four-lane reference ranges to shortlist a forming arrangement, then set finished size from the actual serving volume, seal geometry and filling trial.
- Record whether density was measured loose, settled or under another stated method.
- Keep finished external width separate from the effective tube width used in the calculation.
Stick pack size chart: reference widths and lengths
The table lists the finished-pack ranges of our four-lane reference configurations for each product route. Width is the flat width across the finished stick, set by the forming parts; length runs from cut edge to cut edge and includes both end seals. Inch values are rounded conversions of the millimetre ranges. Read the table as the envelope a machine route can be configured for, not as recommended sizes: a coffee stick, a collagen stick and an electrolyte stick of the same width can still need different lengths, because their powders occupy different volumes at the same weight.
List the smallest and largest doses and the serving planned for launch. Describe how the customer uses it: pouring into water, sprinkling onto food or squeezing directly from the pack. Check opening and emptying with a filled sample, since fitting the dose inside does not mean it will come out easily. Send those observations with the candidate dimensions so the equipment team can assess both filling and use.
Related reading: Multi-Lane Stick Packaging Machines Compared; Coffee Stick Pack Machine & Packaging
Further reading: Powder row: published four-lane reference; Granule row: published four-lane reference; Liquid row: published four-lane reference
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| Product route (four-lane reference) | Finished width | Length | Reference fill range | Pack format |
|---|---|---|---|---|
| Powder (auger per lane) | About 15–30 mm (0.6–1.2 in), set by the forming tube | About 50–180 mm (2.0–7.1 in) | About 1–20 g; around 30 g needs different auger tooling and a trial | Back-seal stick |
| Granule (volumetric cups or vibratory feeding) | About 20–60 mm per lane (0.8–2.4 in) | About 50–180 mm (2.0–7.1 in) | About 1–30 g per stick | Back-seal stick, or four-side-seal sachet about 30–80 mm wide |
| Liquid and gel (pump per lane) | About 15–60 mm for back-seal sticks; about 30–80 mm for four-side-seal sachets | About 50–180 mm (2.0–7.1 in) | About 1–30 ml per stick; up to about 50 ml in four-side-seal sachets | Stick or four-side-seal sachet |
Stick pack types and what "size" refers to
Stick pack, stickpack, stick sachet and stick bag all name the same format: a narrow pack formed from a single strip of film, closed by one seal along its length and a seal at each end. The spelling makes no difference to the specification. Stick pack size means the finished external width and length of the flat pack. When a supplier quotes a size, check that the length includes both end seals and ask how the width is measured across the back seal.
The types in the table change the pack drawing even when width and length stay the same. Each one is produced by forming, sealing or cutting parts, so confirm which are included in the quotation for each planned size before artwork is approved. Shaped outlines beyond these are a separate question; ask for a filled sample before designing artwork around one.
A four-side-seal sachet is a different format rather than a stick type: it is sealed on all four edges and is wider for the same length. Granule and liquid routes can make either format with different tooling. When the choice between the two is still open, settle it before the size, because the format decides which width range applies.
Related reading: Stick Pack vs Sachet: Which Format to Use; Stick Pack Film & Machine Compatibility
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| Type or feature | What it is | What it changes on the drawing |
|---|---|---|
| Back seal (fin or lap) | The single longitudinal seal that closes the film strip into a tube | Uses part of the film width and limits where artwork can sit |
| End seals | Cross seals that close the bottom and top of each stick | Count in the length but not in the usable volume |
| Straight cut | A plain cut between packs | Sets the finished length with the simplest cut line |
| Zig-zag cut | A serrated cut edge | Changes the edge profile and how the pack starts to tear |
| Round-corner cut | Corners trimmed to a radius | Removes sharp corners and needs matching cutting parts |
| Tear notch | A small notch that starts the opening | Has to sit clear of print and code areas |
| Perforated chain | Packs left joined by a perforation instead of being fully cut | Packs travel as a strip, which affects counting and cartoning |
How do you estimate stick pack volume from fill weight?
Divide the dose mass by a measured bulk density to get an approximate product volume for early powder planning. Treat the result as a starting estimate, not a finished pouch calculation: it ignores the seal bands, forming geometry, air carried with the powder and the space needed to keep product clear of the closing jaws. Document how the density was measured and whether the sample represents the production formulation.
Granules introduce additional questions about particle size and segregation. Liquids and gels need consideration of viscosity, temperature and any tendency to foam or leave a dosing tail. The filling system must place the dose within the package during the available cycle. Use a trial to observe the material in motion and after settling. A static sample cup alone cannot reveal what happens when the same product moves through a hopper, auger, pump or nozzle at the proposed operating conditions.
Related reading: Protein Powder Stick Pack Machine; Nutraceutical Stick Pack Machine
Calculate a candidate stick length from fill weight
Use W for the effective flat width of the tube cavity: half the developed circumference available to hold product, excluding material consumed by the back seal. With that definition the ideal circular cross-section is W² / π. An external edge-to-edge reading that includes a fin or other back-seal allowance cannot be substituted directly for W. Obtain the effective width from the agreed tube and seal drawing.
Measure dose mass m and bulk density ρ in the intended filling state, then calculate volume V = m/ρ. Convert ml to mm³ by multiplying by 1,000. The ideal filled-length lower bound is L_min = 1,000Vπ/W², with W in mm. Use the filled sample to establish its average cross-section, end-seal dimensions and clean-closing space. A flatter section needs more filled length than the ideal circular tube of the same developed circumference.
Related reading: Stick Pack Machine Sample Testing
Further reading: Check unfolded strip width and back-seal material
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| Step | Calculation or measurement | Input record |
|---|---|---|
| Product volume | V = m/ρ; mass in g and density in g/ml | Dose specification; density method, sample state and lot |
| Maximum cross-section | A_max = W²/π; effective cavity width W in mm | Forming-tube and back-seal drawing revision |
| Filled-length lower bound | L_min = 1,000V/A_max in mm | Volume and effective width calculated above |
| Candidate finished length | Review actual filled shape, both end seals and filling clearance | Filled samples; approved pack drawing and trial observations |
Discuss this configuration
Discuss on WhatsAppHow to measure stick pack size
Measure finished packs rather than the film or the drawing, and take them from every lane of a trial run, because one lane can differ from the others. Lay each pack flat and use a calliper or a steel rule. Record each reading against its lane, film roll and machine settings so that a later difference can be traced to its cause.
Width and length confirm the drawing, but a filled stick also has a thickness, set by how far the product spreads the tube. Measure it at the thickest point and check it against the carton, dispenser opening or pocket the stick is meant for. A stick that matches the drawing when flat but is too thick when filled has a size problem rather than a filling problem, and the usual fix is a longer pack at the same width.
- Overall width: edge to edge across the flat pack, at right angles to the back seal
- Effective tube width W: derive from the approved tube and back-seal drawing; do not copy an external measurement that includes seal material
- Overall length: cut edge to cut edge, including both end seals
- End-seal depth at each end and the width of the back seal
- Position of the tear notch or perforation relative to the end seal and the print
- Filled thickness at the thickest point
- Lane, film roll, product batch and machine settings for each measured pack
Stick pack dimensions vs usable capacity
Finished pack dimensions describe the outside of the package, including its seals; usable capacity is the smaller space inside those boundaries. Longitudinal seal construction, end-seal depth and the selected forming arrangement all affect that space. A narrow stick and a wider sachet with similar external area should not be treated as interchangeable containers, because their filling openings and formed cross-sections may be very different.
Ask for a drawing showing overall width and length, seals, cut line and opening feature. Mark any size limit imposed by a carton, tray or customer specification. Label provisional dimensions so they can be changed if the trial shows a need for more filling clearance. Record the agreed change on the drawing and share that revision with everyone ordering film or tooling.
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| Field | What to define |
|---|---|
| Width and length | Finished external dimensions, with an agreed drawing |
| Seal layout | Longitudinal and end seals for the selected format |
| Opening | Tear notch, cut style and intended dispensing behavior |
| Artwork | Print repeat, registration and readable information |
| Usable volume | Space available after seal allowances and filling needs |
Allow space for filling and clean sealing
A pack should have enough practical space for the dose to enter and for the seal area to close without contamination. Powder can create dust near the end seal, while a viscous liquid may string between the nozzle and the product already in the pack. These behaviors influence the useful filling interval and the package geometry. Increasing length may help some applications, but it should not replace reviewing the dosing arrangement and timing.
Observe the pack immediately after filling as well as after it has settled. Look for product trapped near the seal, excessive bulging, difficult opening or incomplete emptying. Agree with the supplier which adjustments belong to the package and which belong to the filler. A successful design balances material handling, forming and closure. Do not pick the smallest external rectangle a sample can be pushed into by hand.
Connect the pack drawing to film and tooling
Once a candidate size is selected, the machine team needs to translate it into forming parts, sealing tools, cutting arrangements and a roll-film layout. Multi-lane equipment may slit a wide film web into several narrow strips. The roll width and print layout therefore depend on the actual lane and seal configuration. Do not calculate a production roll order by multiplying a finished width without an approved layout drawing.
Check registration marks, artwork orientation and the reserved code area with the drawing. Even a small size change can move a seal or cut across printed information. Keep the pack drawing, tooling reference and artwork revision together. When any one changes, have the machine team and film supplier review the others before ordering rolls, including when the new size is within the machine's stated range.
Use the artwork design guide to place the scan track, print repeat, cut line and opening features on the approved web drawing before releasing the film order.
Related reading: Stick Pack Artwork & Dieline Design
Further reading: Approve roll layout before printing film
How many stick pack sizes can one machine run?
One machine can run a range of sizes, but every change of dose or geometry is either a settings change or a parts change, and the quotation should say which. Some dose changes are possible through settings within the selected filling configuration. Others need a different auger, forming component, nozzle or cutting part. Ask the supplier to describe the change procedure for each planned product and size, including the parts, tools, setup checks and material needed to confirm the first acceptable packs.
Review the smallest and largest planned package rather than testing only the easiest middle size. If the project includes several recipes, identify which combinations are essential at launch and which are future possibilities. This keeps the initial configuration practical and shows the limits for later. For each proposed material, dose and width, record the required change parts and the output to be checked; a shared catalog range can cover several tooling combinations and operating conditions.
Related reading: Stick Pack Machine Spare & Change Parts
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| Planned change | What usually changes | Confirm with the supplier |
|---|---|---|
| Different width | Forming tube or forming set, plus film roll width and lane layout | Whether a change-part set is quoted for each width |
| Different length, same width | Film feed length and cut position; printed film needs a print repeat that matches | Whether new artwork and registration marks are needed |
| Different dose, same pack | Filler settings inside the dosing range; outside it, different auger tooling or dosing parts | Which doses share tooling and which need a trial |
| Different cut or opening | Cutting parts for zig-zag, round-corner, tear notch or perforation | Which cut styles are included in the quotation |
Evaluate the package beyond the machine discharge
Stick pack dimensions also shape counting, boxing, handling and the customer's experience. Test filled samples inside the intended carton or shipping arrangement, including any inserts. Check whether packs fit comfortably without being forced against edges or folded across seals. If the product will be carried in a pocket or dispensed through a bottle opening, include that use in the review. Small geometric details can matter more in use than they do on a flat drawing.
Opening and emptying should also be evaluated with the actual material. A tear notch can be correctly positioned while the resulting opening remains inconvenient for the product. Compare the retained product after emptying and the ease of handling with dry or wet hands where relevant to the intended use. Record the preferred sample and any rejected alternatives. These observations make later size changes easier to assess because the team knows why the original dimensions were chosen.
Further reading: Packaging World: stick packaging experience and consumer use
Select sizes for a useful filling trial
Select the trial sizes from the combinations that place the greatest demand on cavity volume, filling clearance and opening. Check the largest occupied volume and any narrow filling opening against the actual blend. Distinguish dimensions constrained by cartons or use from dimensions still available for forming-tool review, then record the candidate drawing revision beside each trial.
Keep the trial report with the approved drawing and filled samples. Record the product batch, machine setup, operating conditions and measured dimensions. These provide a comparison if a later formulation or film change affects filling. Send any earlier trial records with your enquiry so we can review the powder, liquid or granule configuration and identify what the next test needs to establish.
Further reading: Carry approved dimensions into acceptance records
Relate density state to the pack and web drawing
Use separate loose and tapped density measurements when assessing a powder’s handling states. Hausner ratio = ρ_tapped/ρ_loose; Carr index = 100 × (1 − ρ_loose/ρ_tapped). Record the method, sample preparation and lot beside both measurements. Calculate the serving volume at each measured state and compare it with the space available during filling. Interpret these indices alongside feed behavior and lane-by-lane weight observations.
To extend the ideal circular lower bound, obtain the average filled cross-section A_filled from the candidate geometry and filled samples. Required filled length = 1,000V/A_filled. Finished length then includes the end-seal widths and the unfilled closing space identified on the tested drawing. Keep these dimensions explicit so a change in density, seal layout or opening feature can be checked against the same physical boundaries.
For a fin-seal drawing, unfold the tube cavity and add the seam material specified at each developed edge. Web width = lane count × strip pitch + outer edge allowances. With that web width B and cut pitch p in meters, basis weight b in g/m² and accepted fraction y, film consumption = B × p × b/(active lanes × y) kg per 1,000 accepted packs. Compare candidate lengths only after the same dose and clean closure have been demonstrated.
Common Questions
How do I convert grams into stick pack dimensions?
You cannot convert them directly. Start with an approximate volume from dose mass and measured bulk density, add room for seal bands and clean closing, then draw a candidate pack. A filled sample from a trial confirms the width and length, because settling and dosing behavior do not show up in the weight.
Is there a standard stick pack size?
No. Retail cartons, dispensing habits and product density vary too much for one standard. The length and width ranges quoted for our four-lane machines describe what the forming parts can produce, not a size to copy. Fix the dimensions from your tested serving and your carton or shelf limits.
What size is a sugar stick?
There is no single sugar stick size. Sugar sticks are granule stick packs, and the granule reference configuration forms back-seal sticks about 20–60 mm wide per lane and about 50–180 mm long, with fills of about 1–30 g. Work out the length from your portion and the measured bulk density of the sugar you will run, then confirm it on filled samples.
Do I need new tooling for every stick pack size?
Not always. A dose change inside the same pack can sometimes be handled by settings, while a new finished width usually means a different forming tube or cutting part. Ask for a written list of which planned sizes share parts and which need their own set before you order film.
How much empty space should a stick pack leave above the product?
Enough to keep product out of the end seal while the jaws close, which varies with dust, settling and nozzle tail. There is no single figure. Judge it from trial packs checked straight after filling and again after settling, looking for trapped product in the seal or excessive bulging.