The rise of the stick pack: Optimizing your production line for single-serve success

Introduction

The shift toward on-the-go convenience has made stick pack packaging one of the fastest-growing formats in the manufacturing world. From hydration multipliers and instant coffee to single-dose pharmaceutical applications, this sleek, eco-friendly alternative to the traditional sachet is taking over the shelves.

For packaging engineers and plant managers, the benefits are clear: reduced material costs and higher filling speeds. However, as production speeds increase and package sizes decrease, a critical challenge emerges: The Code.

How to maintain high-resolution, compliant traceability on a tiny, flexible strip of foil moving at breakneck speeds

Videojet understands that coding solutions should be as innovative as the packaging itself. Here are key considerations for manufacturers when updating or adding coding equipment to stick pack lines.

How do you balance speed and quality in stick pack production?

Stick packs are the gold standard for high-volume powder packaging and liquid fills. However, because they are produced on multilane Vertical Form, Fill, and Seal (VFFS) machines often outputting hundreds of packs per minute, the coding challenge is significant.

The Challenge

If your coding equipment cannot keep pace with your stick pack machine, you face two risks:

1. Bottlenecks: The printer becomes the slowest part of the line, capping your total throughput.
2. Quality Drift: At high speeds, inferior printers may produce smeared, ghosted, or misaligned codes. In pharma, an illegible code is a recall waiting to happen. For food and beverage manufacturers, it’s a brand integrity issue.

The Fix

Depending on your setup, you need a coding technology designed for intermittent or continuous motion integration. The printer must be able to print across the web quickly before the film is slit into individual sticks.

What challenges do substrates like foil, film and paper present?

Stick packs are rarely just “paper.” They are complex laminates often including aluminum foil for barrier protection. Coding equipment must be able to handle the challenges of these materials:

• Flexible film: Prone to stretching or wrinkling if the printhead pressure is incorrect.
• Foil: Highly reflective and non-porous, requiring inks that dry instantly and adhere aggressively to avoid rubbing off during the “fill and seal” friction.

How do you solve the “real estate” problem on stick packs?

A stick pack is narrow, sometimes only 20mm wide. Yet, you may be required to print:

• Lot Number
• Expiration or best by date
• 2D Data Matrix / QR Code (for consumer engagement or serialization)

On stick packs, these kinds of codes often require micro-printing capabilities. The code must be crisp and machine-readable (grade A or B) even when scaled down to fit the “white space” of the design.

Which coding technologies work best for stick packs?

Choosing the right coding technology for stick pack packaging involves a detailed assessment of the production environment, packaging materials, and operational requirements. A consultative approach helps manufacturers identify solutions that align with their specific production goals, while addressing the unique challenges of stick pack applications. Key considerations include line speed, substrate compatibility, code content, and environmental factors, all of which play a crucial role in selecting the most suitable option for efficient and reliable performance.

For stick packs, two coding technologies stand out for their compatibility and versatility.

Comparison of best coding technologies for stick pack packaging

Technology	Best suited for	Why it wins	The Videojet advantage
Thermal transfer overprinting (TTO)	High-speed film and foil webs	TTO is a proven and efficient solution for flexible packaging, delivering high-resolution (300 dpi) printing of variable data such as dates, barcodes, and logos directly onto the film web.	Modern TTO systems maximize ribbon economy, reducing changeover downtime and lowering cost-per-print.
Laser marking	High-volume lines requiring permanence and enhanced consumer convenience	Lasers ablate the top layer of the stick pack material to create a code that cannot be rubbed off or altered, ideal for pharmaceutical compliance and anti-counterfeiting.	With no inks or consumables to replenish, lasers offer a low Total Cost of Ownership (TCO) and fluids-free production environments.

FAQs

Whether you are packaging probiotic powder or soy sauce, your coding equipment should be an enabler of success, not an obstacle. We focus on integration: ensuring our printers mount seamlessly into your specific stick pack machine (e.g., OMAG, Universal Pack, etc.) and communicate flawlessly with your HMI.

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