Stick Pack vs Sachet: The Ultimate Guide to Key Differences

In today’s fast-paced world, single-serve packaging has exploded in popularity for items ranging from coffee and supplements to lotions and condiments. Two common formats – stick packs and sachets – look similar at first glance, but they have important differences in shape, materials, and production. Stick packs are long, narrow tubes sealed on one side and both ends, while sachets are flat, pillow-like packets with three- or four-sided seals. Each format offers unique advantages for portion control, branding, and convenience. In this guide, we’ll explain what stick packs and sachets are, compare their design and manufacturing, and outline the pros and cons of each. By the end, you’ll understand which packaging style best fits different product needs and manufacturing capabilities.

What Is a Stick Pack?

Stick packs (also called stick packets or stick packages) are slim, tube-shaped pouches typically made from laminated film. They are designed for single-serve doses – imagine an individual packet of instant coffee, drink mix, or a vitamin supplement. Stick packs are much longer than they are wide, usually about 3–5 times longer (for example, ~1–2 cm wide and 8–12 cm long). This elongation gives them a narrow opening at one end for pouring or squeezing out the contents. A finished stick pack usually has one longitudinal (side) seal and two end seals (top and bottom). The resulting tube holds a measured portion of product securely and compactly. Typical contents include fine powders, granules, or liquid concentrates – think sugar or sweetener sticks, single-serve coffee, electrolyte drink mixes, or even liquid gel samples.

Because stick packs are so compact and lightweight, they are extremely portable. The slim design fits easily in a pocket or bag, making it ideal for on-the-go use. Manufacturers form stick packs on vertical form-fill-seal (VFFS) machines that wrap continuous film into tubes and seal them quickly. Modern multi-lane stick pack machines can reach astonishing speeds – for example, 20-lane machines can run at over 80 packs per minute per lane (over 1,600 sticks per minute total). This high throughput and reduced film usage make stick packaging a cost-effective solution for large-volume products. Companies like Jinlu Packing supply advanced stick pack machines (VFFS systems) that automate the entire process of forming, filling, and sealing these narrow packs, ensuring precise dosage and strong seals.

What Is a Sachet?

Sachets (or flat packs) are small, flat pouches typically used for single-use portions as well. Unlike the tubular stick packs, sachets are sealed on three or four sides and have a much more rectangular (or square) profile. A classic sachet might be 4–8 cm wide and 5–10 cm tall, giving it a generous surface area for graphics and labeling. Common examples include sugar packets, instant tea bags, shampoo samples, condiment packs (like ketchup or mayonnaise sachets), and single-dose skincare or pharmaceutical samples.

Modern sachets are usually made from multi-layer laminated materials (combinations of plastic, foil, and sometimes paper) to provide a good barrier against moisture and oxygen. They are sealed using either vertical or horizontal form-fill-seal machines. In a VFFS sachet line, a roll of film is folded into a tube and sealed on the sides, then filled and sealed at the bottom and top. In a horizontal (HFFS) machine, one roll forms the back panel and another forms the front, and vertical side seals hold them together. Either way, a sachet ends up as a sealed bag, often with a tear notch or easy-tear feature for user convenience.

Because sachets are flatter and often wider, they can accommodate a wider variety of products (liquids, pastes, gels, or solids) and larger portion sizes than stick packs. However, their bulkier shape means they are not as slim in the pocket. The extra material and seals allow for detailed printing (logos, usage instructions, nutritional facts, etc.) on both sides of the pack. In summary, sachets offer versatility and branding space, while stick packs excel at compactness and precision dosing.

Key Design Differences

• Shape & Seals: Stick packs are narrow and tubular (sealed on one side and both ends), whereas sachets are flat, rectangular pouches sealed on at least three sides. This means stick packs typically use one continuous film folded into a tube, while sachets can use folded film or two panels.
• Dimensions: Stick packs commonly have a length-to-width ratio of about 3:1 to 5:1, making them long and slender. Sachets tend to be more square (width-to-length ratio ~1:1 to 3:4), offering roughly even dimensions or a modest rectangular shape.
• Material Usage: Because stick packs use a simple tube form, they usually consume significantly less packaging film than a comparable sachet. In practice, stick packs can use 15–40% less material per portion than a flat sachet. Fewer layers and the tubular shape mean less waste per unit, which can lower costs and environmental impact. Sachets, by comparison, use more material (each side must be sealed, and often extra backing), but they allow for larger contents and printing area.
• Dispensing: Stick packs have a narrow opening ideal for pouring or squeezing small amounts with precision. This makes them great for powders and fine liquids. Sachets have a wider opening (once torn) which may be messier for pouring powders, but they accommodate thicker liquids or creams better. The wide format makes sachets easier to fill and seal with different products.
• Branding Space: A sachet’s flat panels provide much more surface area for branding, text, and instructions. Stick packs have limited space (usually a logo and minimal text along the tube), which can be a drawback if extensive product information is needed.

Advantages and Disadvantages

Both stick packs and sachets offer convenience and single-use portioning, but each has trade-offs.

• Pros of Stick Packs: Stick packs are ultra-portable (they easily fit in a pocket or bag). They tend to use less packaging material, making them cost-effective and generating less waste. The tubular design provides a controlled, narrow opening, which helps dispense contents neatly. Because stick packs are filled and sealed continuously on high-speed machines, they support very high production rates. Modern stick pack film is usually multi-layered, giving good barrier protection against moisture and light.
• Cons of Stick Packs: The slim profile limits the space available for branding and information. Stick pack production requires specialized equipment and precision sealing; the machines and tools can be more expensive or complex than for sachets. Stick packs are also less suitable for bulky or irregularly shaped products, since those might not flow easily through the narrow fill tube. If not designed well, stick packs can be hard to tear open.
• Pros of Sachets: Sachets are highly versatile – they can hold powders, granules, gels, creams, and small solids (tablets, capsules). They have plenty of room for color graphics, logos, instructions, and legal text. Filling and sealing machinery for sachets is widely available (both vertical and horizontal types), often making sachet packaging easier to set up for different companies. Sachets often include easy-tear notches, which improve the user experience. They are excellent for trial samples and products needing precise, larger single servings.
• Cons of Sachets: Sachets are generally bulkier than stick packs, so they’re slightly less space-efficient in bags or pockets. They tend to require more film per unit – more plastic means higher material costs and more waste. The wider opening of a sachet can make pouring fine powders or liquids a bit messier. Overall, sachets can be more expensive per unit to produce, though this is offset if a larger fill volume is needed.

Manufacturing Process: Stick Pack vs Sachet Machines

Stick Pack Production:

1. Material Preparation: Start with a roll of laminated packaging film (often layers of plastic, foil, etc.). The film is unwound and kept under tension. Modern machines can use a single thin film rolled in, saving space and weight.
2. Forming the Tube: The film is guided over a forming collar on a vertical form-fill-seal (VFFS) machine. The film edges overlap and are sealed vertically, creating a continuous tube. This longitudinal seal runs along what will be the back (flat) of each stick pack.
3. Bottom Sealing: A horizontal heat-seal closes the bottom of the first pouch, forming the base of the stick packet.
4. Filling: The measured product (powder, liquid, etc.) is dispensed into the open top of the tube via a gravity hopper or auger feeder. Precise dosing ensures each pack contains the correct quantity.
5. Top Sealing & Cutting: A top heat-seal is applied above the fill. Immediately after sealing, the continuous tube is cut between seals to separate each stick pack. The result is an individual sealed stick packet, and the process repeats for the next one.

Modern stick pack machines often have multiple lanes (2, 4, 8, or more forming collars in parallel), multiplying output. These machines are fully automated – adding the roll of film, programming portion sizes, and running at high speed. Because the entire process happens in a single machine, stick packs are typically made exclusively by automation (no pre-made stick pouches exist).

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Sachet Production:

1. Material Preparation: Like stick packs, sachets use laminated films. The machine may use one roll (folded to form both front and back) or two rolls (one for front panel, one for back). Paper-based films can also be used for eco-friendly sachets. The film is unwound and fed to the forming section.
2. Forming the Pouch: Sachets can be formed in a vertical or horizontal FFS machine. In a vertical line, one film is folded into a tube and sealed on one side. In a horizontal line, two films meet edge-to-edge and are sealed on both sides to form a flat pouch. The result is a three-sided open pouch.
3. Side Sealing: If using separate films, vertical seals are applied along the sides of the sachet. This creates the characteristic three- or four-sided seal pattern of sachets.
4. Bottom Sealing: A horizontal seal closes the bottom of the sachet pouch. The pouch is now ready to be filled from the top.
5. Filling: The product is filled into the open sachet. Because the opening is wider, a variety of filling systems (volumetric, liquid pumps, etc.) can be used. Care is taken to dose accurately.
6. Top Sealing & Cutting: After filling, a final horizontal seal closes the top of the sachet. The finished sachet may then be cut or perforated for easy separation from the film web.

Sachet machines are flexible: vertical sachet machines are common for powders and granules, while horizontal sachet machines can fill liquids and gels. Equipment for sachets is often easier to source and scale for low-volume or specialty lines (manual dosing can even be done on some small sachet machines).

Common Applications

The choice between stick pack and sachet often comes down to the product and use-case. Stick packs shine for on-the-go consumables and pharmaceuticals that require a precise, small dose. Examples include powdered drink mixes (coffee, tea, electrolytes), sugar or sweetener sticks, vitamin/mineral supplements, or single-dose medicines. For instance, popular products like Crystal Light® drink mix or single-serve probiotic powders use stick packaging. Because stick packs use less material and are so portable, they are preferred when minimal footprint and controlled dispensing matter.

Sachets, by contrast, are ideal when more volume or durability is needed. Common uses include sauce and condiment pouches (ketchup, salad dressing), cosmetic/skincare sample packs (shampoos, lotions, face masks), food seasoning packets, and shower gel or shampoo sachets. They’re also used in pharmaceuticals (e.g. single-dose powders, topical creams) and personal care where the product might be thicker. The larger pouch and easy-open design make sachets suitable for viscous or wet products.

Geographically and by industry, stick packs are especially popular in the beverage and supplement sectors, and wherever travel-sized dosing is key. Sachets dominate in the food, condiment, cosmetic, and household chemicals sectors. Both formats support a “try-me” or sample market well – since they deliver a controlled single use, they encourage trial and travel convenience.

Environmental & Cost Considerations

From an environmental standpoint, stick packs generally win on material efficiency. Their narrow, tube shape means up to 15-40% less plastic per unit compared to an equivalent sachet. Using less film and fewer layers reduces raw material costs and waste. Stick packs can also be made with advanced lightweight films or even recyclable materials. Sachets often use more film and possibly an extra layer (especially 4-seal sachets), so they generate more packaging waste per dose. However, sachets can sometimes be produced with paper-based or compostable films that are more eco-friendly.

In terms of cost, stick packs require specialized machinery (the VFFS stick pack machines) and precise handling, which means higher upfront equipment investment. But the high output and material savings can lower per-pack cost at scale. Sachet lines are generally cheaper to set up (especially for small runs) and more forgiving on material registration, but they use more substrate. Overall, stick packs are often more cost-effective for large-volume, powder-based products, while sachets may be more economical when larger fill sizes or diverse products are needed. Choosing the sustainable option depends on balancing material type, recyclability, and production efficiency.

Choosing the Right Option

So, how do you pick between a stick pack and a sachet? It comes down to your product and market needs. If you need a small, precise dose of a free-flowing product and portability is key (e.g. travel drink mixes, sugar, vitamins), a stick pack is probably the best match. If your product is thicker, requires more volume, or you need extra space for branding and instructions (e.g. sauces, lotions, condiments), a sachet is likely better. Consider also your filling equipment: stick packs must be filled on dedicated stick-pack machines (often multi-lane), whereas sachets can be filled on a wider variety of machinery. Finally, factor in cost and branding – sachets offer more design area, whereas stick packs often reduce material costs. In short: match the pack form to the product’s consistency, portion size, and how consumers will use it.

Conclusion

Stick packs and sachets are both valuable single-use packaging formats, each optimized for different situations. Stick packs provide slim, efficient packaging ideal for powders and concentrates, while sachets offer larger, more versatile pouches for a variety of products. By understanding their design differences, manufacturing requirements, and use cases – as we have outlined above – manufacturers can make an informed choice. Whether you’re packaging pharmaceuticals, food ingredients, or personal care samples, choosing the right format (and the right machines, like those from Jinlu Packing’s stick-sachet packing machine line) will help ensure product quality, consumer convenience, and cost-effectiveness.

FAQs on Stick Pack vs Sachet

References：
1.Sachet and Stick Packaging Machine Market Size, Share & … — Straits Research Report, 2024.
2.Optimizing Product Packaging and Oral Drug Delivery with Stick Packs (2025) — Author(s) from Catalent