Stick Pack Sachets for Instant Drinks: Sizes, Weights and Formats
Quick answer: Stick pack sachets are long, narrow sachets, sealed along the back and at both ends, that hold one serving of powder. They are the most common pack for instant coffee, tea and latte drinks because they are easy to pour, use little film and pack neatly into boxes. Instant drinks usually need 12 to 14 g per stick, while sweetener and topping sticks hold 1 to 2 g.
If you are planning your own instant drink brand, the sachet is the first thing your customer touches. In fact, the format you choose affects how the drink pours, how many sachets fit in a box, how much space your design has and even how the product is produced. So this guide explains stick packs for instant drinks in plain terms, using the formats we run on our own line in Sohar Free Zone, Oman.
One cup, one stick
Long, slim and easy to tear: why the stick pack became the standard for instant karak, cappuccino and lattes.
What Is a Stick Pack?
A stick pack is a slim, tube-like sachet. It has one seam running down the back and a seal at the top and bottom, and it is usually about four times longer than it is wide.[1] A flat sachet, by contrast, is a small square or rectangle sealed on three or four sides.[1]
| Stick pack | Flat sachet | |
|---|---|---|
| Shape | Long and narrow | Square or rectangular |
| Seals | Back seam plus top and bottom | Three or four sides |
| Pouring | Pours in one stream into a cup | Wider opening, can spill |
| In the box | Stands upright, packs tightly | Lies flat, takes more space |
| Typical use | Instant coffee, tea, lattes, sweeteners | Samples, larger single doses |
Why Stick Packs Suit Instant Drinks
- One serving, measured: each stick holds the exact dose for one cup, so every cup tastes the same.
- Clean pouring: the narrow opening sends the powder straight into the cup.
- Less film: a slim shape uses less packaging material per serving than a wide sachet.
- Compact boxes: sticks stand side by side, which suits shelf boxes, hotel trays and office pantries.
- Fresh until opened: each serving stays sealed until it is used.
Stick Sizes and Fill Weights
In general, stick packs are described by width and length, and by the weight of powder inside. For example, on our line we run two stick widths: a wider stick about 4 cm across for the main drink, and a narrow stick about 2.5 cm across for small doses such as toppings. As a guide, typical fill weights for our own drinks are:
| Drink | Fill weight per stick |
|---|---|
| Karak tea | 12 g |
| Coffee mix (2 in 1) | 12 g |
| Cappuccino | 14 g |
| Matcha latte | 14 g |
| Date latte | 14 g |
| Stevia sweetener | 1 g |
| Toppings (for example saffron, pistachio, freeze-dried fruit) | 1 to 2 g |
However, the right weight depends on the recipe and the cup size you have in mind. A richer, foamier drink usually needs more powder than a simple coffee mix. So confirm the dose with samples before you design your packaging, because the stick length and box size follow from it.
Main Sachet Plus Topping Sachet
Some drinks are better when part of the recipe stays separate until the last moment. A freeze-dried strawberry topping, for example, keeps its colour and crunch best when it is not mixed into the creamy powder. In that case a small topping stick is attached flat to the back of the main stick, so the customer gets both in one piece: they make the drink with the main stick, then sprinkle the topping on top.
The same idea also works for sweetness. Instead of sweetening the mix, a separate 1 g stevia stick can be attached, so each drinker decides how sweet their cup should be. Read more about toppings and about stevia Reb-M.
How Stick Packs Are Filled and Packed
First, a multi-lane machine cuts a roll of printed film into several narrow strips. Then each strip becomes a tube, which the machine fills with a measured dose of powder, seals and cuts. As a result, the machine makes several sticks side by side at the same time. Our main machines, for instance, run five lanes. An auger filler, a rotating screw, measures each serving of powder, while a cup filler doses freeze-dried pieces or granules.
After filling, the line counts the sticks into boxes, a jet printer adds the batch and dates, and finally each box passes a checkweigher and metal detector. For the full process, see how instant drink powders are made.
Design Tips for Stick Packs
- Keep the front simple: a narrow stick has little space, so brand, flavour and one key message are usually enough.
- Use Arabic and English: products sold in the GCC need Arabic labelling, so plan both languages from the start.
- Know where the legal text goes: if sticks will be sold one by one, each stick may need its own full label. However, if you sell them only in boxes, most details go on the box. Check the rules for your market, for example SFDA labelling basics for Saudi Arabia.
- Leave space for coding: also keep a clear area for the printed batch number and dates.
- Mark the tear point: a notch or tear line makes the stick easier to open with dry hands.
- Use your manufacturer’s template: always design on the exact film width, repeat length and seal areas the manufacturer gives you.
Your drink in your own stick packs
We produce instant drink sticks for brands and distributors in Oman and the GCC. Also ask us about formats and samples.
Quick questions
What is the difference between a stick pack and a sachet?
A stick pack is a type of sachet: long and narrow, with a back seam and end seals. In contrast, a flat sachet is square or rectangular and sealed on three or four sides.
How many grams are in an instant coffee stick?
It depends on the drink. For example, simple coffee mixes are often around 12 g, while creamy drinks such as cappuccino or lattes are often around 14 g per stick.
Can a topping be packed separately?
Yes. A small topping stick can be attached to the back of the main stick, so the topping stays fresh and crunchy until it is used.
Can each stick carry my brand?
Yes. With private label, the printed film carries your own design on every stick.
Planning for an office or hotel? Work out how many sachets you need each month with our office and hotel coffee calculator.
References
- ePac Flexible Packaging. Stick pack vs sachet packaging: what’s the difference? epacflexibles.com
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