Stick Pack vs Sachet: The Ultimate Guide to Key Differences
November 5, 2025
Discover the key differences between stick pack and sachet packaging. Learn about their design, production
The pharmaceutical and nutraceutical sectors operate under a non-negotiable principle: absolute accuracy. Packaging is not merely the final step; it is a critical control point directly impacting patient health and regulatory compliance. The industry has rapidly moved away from manual counting methods, which were prone to human error and time wastage, toward robust automation.
For decades, many operations relied on the simple tablet counter tray combined with human effort. This manual approach is now recognized as a historical curiosity—a “herculean task ruled by elaborate human error and time wastage” that modern manufacturing can no longer afford. The shift to automation is fundamentally rooted in risk mitigation and regulatory necessity. If a patient receives too few pills, their treatment could be interrupted; if they receive too many, it could be dangerous. This responsibility demands machines that deliver verifiable, consistent accuracy, transforming the investment in a state-of-the-art tablet counting machine from an efficiency upgrade into a patient safety mandate.
So, what exactly is a modern pill counter machine? A tablet counter is an electronic machine designed to automatically count and efficiently dispense specific doses of pills, capsules, tablets, and softgels into bottles or containers. These machines are vital in drug manufacturing, packing plants, and pharmacies globally, providing the verifiable, consistent accuracy required to meet patient safety mandates.
The impressive performance metrics of modern automatic counting machines are based on sophisticated integration of mechanical separation and high-speed sensing technology. Achieving pinpoint accuracy requires the product to be perfectly separated before it reaches the counter.
The counting process begins when tablets are loaded into a hopper. They are guided by gravity and a controlled vibration system. High-precision counters rely on a sophisticated vibrating feeding system to ensure product singulation—meaning each tablet or capsule is spaced out and handled individually. For particularly difficult items like sticky gummies or irregular tablets, specialized systems, such as a 3-stage vibration system, are often employed to ensure consistent separation.
The core of any electronic counting machine is its sensor technology. The industry standard utilizes Optical Sensors, primarily infrared (IR) detection or opposed-mode sensors (through-beam). These opposed-mode sensors are highly reliable because they operate by detecting when a tablet breaks a high-speed light beam, a process largely unaffected by the tablet’s color or reflectivity. These systems scan extremely fast, often up to 16 times per millisecond, guaranteeing precision even when thousands of units are falling rapidly.
Packaging lines often face challenges like dust and powder residue that can accumulate and cause miscounts. To counter this, some manufacturers integrate the Electrostatic Field Sensor (E.F.S.). This unique, dust-resistant sensor goes beyond simple counting. By measuring product mass against a reference curve, the E.F.S. can discriminate between a good product and foreign elements like broken tablets or empty capsules, ensuring precision even with dusty products.
The selection of a tablet counting machine depends on production capacity, required accuracy, and budget.
Manual Counting relies entirely on human labor and is highly error-prone, limiting its use to R&D or extremely low volumes. The Semi-Automatic Counting Machine automates the core counting process but still requires human intervention for feeding and container handling. These are portable and ideal for smaller pharmacies or mid-sized businesses requiring moderate automation at speeds up to 1,000 units per minute.
Fully Automatic Electronic Counters are designed for continuous, high-volume industrial use and are integrated into complete bottling lines. They can handle outputs ranging from 4,000 to 6,000 tablets per minute, supporting line speeds of 100 or more bottles per minute (BPM). While the initial investment (CAPEX) is higher, typically $5,000 to over $50,000 , this is justified by reduced operational expenses (OPEX) from labor savings and superior accuracy.
Modern lines must handle complex forms, such as sticky gummies or softgels. This requires specialized counting machinery, like dedicated gummy counting machine or softgel capsule counters , which utilize sophisticated mechanical feeding systems designed for irregular or sanitary handling.
Investing in advanced automatic counting technology is a key strategy for financial security, quality assurance, and regulatory compliance.
Modern electronic counters deliver documented accuracy rates of 99.99 percent at high speeds, eliminating the uncertainty of human handling. Jinlu’s high-speed models, for instance, guarantee accuracy exceeding 99.98%. This precision is paramount for patient safety and maintaining public confidence.
A major financial advantage is the direct elimination of product waste associated with older measurement techniques. Relying on packing by weight often leads to costly product giveaway (overcounting) due to the slight variability in individual pill weight. For high-value pharmaceuticals, this cumulative waste significantly impacts profit margins. Optical precision counting, in contrast, guarantees 100% accurate portion control by counting every single piece, maximizing ROI and ensuring exacting portion control.
Pharmaceutical manufacturers must adhere to strict FDA and current Good Manufacturing Practice (CGMP) standards. The FDA mandates that quality must be built into the manufacturing process. Automated, verifiable counting provides the necessary process control to ensure manufacturing conditions are reliable and reproducible. Electronic tablet counter machines provide the high accuracy and necessary traceability data required for audits, thus safeguarding consumer health and regulatory integrity.
High-end automatic tablet counter machines are now incorporating cutting-edge computer vision systems.
While traditional optical (IR) sensors are accurate, their speed is limited because tablets must be physically separated (singulated) to prevent miscounts—a critical bottleneck. The newest generation of professional counters integrates high-speed camera vision systems that eliminate this mandatory physical singulation step. This allows for a substantial speed breakthrough, often boosting production output by two to three times.
Furthermore, vision systems merge counting with quality control, enabling real-time analysis to detect and reject non-conforming items, such as those with wrong color (cross-contamination), physical defects, or damage. By automatically rejecting defective products as they are counted, a vision-based system ensures strict cGMP compliance and drastically lowers the risk of costly product recalls. Future developments also emphasize connectivity, incorporating features like real-time data management and remote monitoring.
[jl_youtube src=”https://www.youtube.com/embed/qnq_rgiqHPM”]
Selecting a capital expenditure like an industrial pills counter requires meticulous assessment of Total Cost of Ownership (TCO), integration ease, and long-term reliability.
Accurately define critical capacity (BPM or units per minute) and ensure the machine’s feeding systems are robust enough to handle all your challenging products, including sticky or oddly shaped items.
The counter must seamlessly fit within the available production space (footprint) and integrate smoothly with both upstream (unscramblers) and downstream equipment (cappers, labelers). To minimize downtime, prioritize user-friendly machines with intelligent PLC controllers and modular designs where product contact parts can be quickly disassembled, cleaned, and reassembled without tools. Machines that store servo-controlled settings within product recipe files enable swift changeovers, maximizing operational uptime.
Strict operational protocols are essential to maintain the guaranteed accuracy and compliance of any tablet counting machine.
A rigorous cleaning routine must be established and followed after every production batch to prevent residue accumulation and cross-contamination—a serious GMP violation. The design of the machine should facilitate this, ideally featuring tool-free disassembly to ensure all product contact parts are accessible and easily cleaned. Comprehensive staff training is paramount, covering operation, safety, and common troubleshooting to prevent user-induced errors.
While rare in advanced systems, production teams must be prepared for challenges. For instance:
Jinlu Packing is a recognized authority in automatic counting solutions, relied upon by global pharmaceutical leaders, including GSK and Robinson-Pharma.
Jinlu machines utilize superior craftsmanship and top-grade components to ensure pinpoint accuracy. The portfolio offers models capable of handling standard tablets and capsules (2-40mm) as well as complex items like gummies (2-130mm), including those with oil, powder, or sugar coatings, all within a sanitary design.
Jinlu’s automatic counters are designed for seamless integration into continuous, high-speed bottling lines, connecting efficiently with bottle unscramblers, cappers, and labelers.
Jinlu’s high-throughput models, such as the Tablet Capsule Counting Machine (16H), guarantee an industry-leading accuracy rate of greater than 99.98%.
Table: Jinlu Automatic Counting Machine Performance Overview
| Jinlu Model (Example) | Max Capacity (BPM) | Applicable Item Size | Guaranteed Accuracy Rate | Specialty Focus |
| Tablet Capsule Counting Machine (8C) | 50 BPM | 2-40mm Capsule, Tablet, Pill | >99.8% | Medium-Scale, High Accuracy |
| Tablet Capsule Counting Machine (16H) | 100 BPM | 2-40mm Capsule, Tablet, Pill | >99.98% | Maximum Industrial Throughput (Flagship) |
| Gummy Counting Machine (16R) | 80 BPM | 2-130mm (Gummy, Candy, etc.) | >99.97% | Irregular/Sticky Product Handling |
Jinlu offers a generous 3-year warranty on core electrical components and provides lifetime machine maintenance. For rapid deployment, fully stocked counting machines are available for delivery within three days at the fastest. Support is guaranteed via global on-site service and dedicated service centers in the US and Hong Kong, ensuring expert assistance and minimal downtime risks.
Choosing a tablet counter is a strategic decision impacting financial health, regulatory standing, and patient trust. The advanced tablet counting machine offers accuracy levels (often 99.99%) that eliminate the inherent risks of manual or weight-based counting, safeguarding profits by stopping costly product giveaway.
To meet scaling demands and ensure compliance, prioritize technology featuring high-speed optical systems, superior handling for complex products, seamless line integration, and user-friendly, tool-free maintenance designs.
Secure your line’s future by partnering with a proven industry leader. Jinlu Packing offers machines engineered for maximum throughput and accuracy (>99.98%) backed by a robust global service network and exceptional warranties. Contact Jinlu Packing today to leverage our R&D expertise; our team can provide tailored drawings and layout recommendations within one hour of inquiry.
The primary function of a tablet counter is to count solid dose products (tablets, capsules, softgels, gummies) with near-perfect accuracy (up to 99.99%) before dispensing them into containers. Beyond counting, it serves as a critical Quality Control (QC) checkpoint to prevent costly undercounts (regulatory risk) and overcounts (profit loss).
Accuracy is critical because any miscount violates cGMP (Current Good Manufacturing Practice) standards. Undercounting can compromise patient safety and lead to product recalls, while overcounting results in significant financial loss from product giveaway. A high-accuracy pill counter machine protects both patient health and the company’s compliance record.
The three main types are:
1.Manual: Used only for very low-volume R&D.
2.Semi-Automatic: Tabletop units requiring manual bottle placement, suitable for small to medium batches.
3.Fully Automatic: High-speed, multi-channel machines integrated into a complete packaging line, essential for large-scale pharmaceutical production.
They achieve high accuracy primarily through two integrated systems:
1.Vibratory Feeding: Plates vibrate to perfectly singulate and spread the products into single streams.
2.Optical/Photoelectric Sensors: High-speed light beams detect each unit as it passes, electronically registering the count.
Powder and dust can interfere with optical sensors. High-end tablet counting machines are equipped with dedicated anti-dust features, such as electrostatic field sensors (E.F.S.) or targeted vacuum ports, which actively clear the counting channels and sensors to maintain accuracy above 99.9%.
Electronic counting is superior because it guarantees 100% count accuracy for every unit. Weight-based filling can result in an incorrect quantity if the individual tablets or capsules have slight weight variations, which is common. This makes counting non-negotiable for regulatory assurance.
The biggest challenge is clumping and jamming due to the sticky coatings, which causes miscounts and significant downtime. This is solved by specialized gummy counting machines that use modified, multi-stage vibration systems, wider channels, and non-stick coatings designed to maintain unit separation and flow.
The five most critical criteria are:
1.Accuracy Rate (Insist on >99.9%).
2.Changeover/Cleaning Time (Must be tool-free and fast for GMP).
3.Product Versatility (Can it handle all your product types, e.g., softgels, tablets, gummies?).
4.Integration (Can it fit seamlessly into your existing line?).
5.After-Sales Service and Warranty.
The primary financial benefit is the elimination of product giveaway (overcounts) and the maximization of production throughput. By achieving reliable speeds (e.g., 100 bottles per minute) and drastically reducing costly human errors, the machine significantly lowers the operational cost per unit.
The key emerging trends are Vision-Based Counting Systems. These systems use industrial cameras and AI/Computer Vision to see and count products, which can eliminate the bottleneck of perfect singulation, offer significantly faster speeds, and simultaneously check for broken or defective products.
References：
1. How to Use Photoelectric Sensors for Tablet Counting — Banner Engineering Corp.
2.Innovations Driving Automatic Tablet Counting System Market 2025-2033 – MarketReportAnalytics
Discover the key differences between stick pack and sachet packaging. Learn about their design, production
Learn what is a sachet and how sachet packaging works. Discover types of sachet packs, benefits
Pharmacy blister packs seal each pill in its own pocket, guarding medicines from moisture, air and
Discover the essential factors to consider when buying capsule filling equipment. Learn about precision, speed, versatility,
Friendly Links: Rich Packing | Capsule Filling Machine Manufacturers