Custom Stick Pack Packaging

Packaging single-serve drink mixes, travel-size supplements, or instant coffee portions for customers who are always on the move? Iva Pak’s custom stick pack packaging is your answer — delivering the perfect combination of compact functionality, premium print quality, and production-line reliability. Engineered for precision, built for portability, and available in as little as 10 business days.

Our Lay Flat Pouch

Clear Window Pouches

Showcase the quality of your product and build consumer trust in your brand from the very first glance.

Build Your Pouch

No Window Pouches

Maximize your print real estate with full-coverage branding across every surface of the pouch.

Build Your Pouch

Kraft Paper Pouches

PouchesA natural, eco-friendly aesthetic that resonates with organic and artisan consumers — available with full barrier inner layer for complete product protection.

Build Your Pouch

Precision-Engineered to Run on Your Equipment

Iva Pak stick pack rollstock is delivered precision-converted to match your form-fill-seal machinery — or your co-packer’s setup — exactly. From first-run test batches to full-scale ongoing production, our digital printing technology gives you professional-grade stick pack packaging without plate fees, without excessive setup costs, and without lead times that hold your launch back.

Make Every Stick Pack Sell for Your Brand

Even in a compact stick pack format, your print finish is a brand decision that consumers notice. Choose the finish that makes your stick pack stand out in a display, on a shelf, or in a consumer’s hand.

  1. Gloss — Sharp, Vivid, and Hard to Ignore
    A high-shine coating that intensifies colors and creates immediate visual impact — even at stick pack scale. The natural choice for high-energy brands, sports nutrition, and any brand that wants to be the first thing a consumer reaches for in a display.
  2. Matte — Clean, Modern, and Deliberately Premium
    A flat, non-reflective surface that communicates considered quality and brand maturity. Photographs beautifully, resonates with clean-label and wellness-focused consumers, and gives your stick pack a refined, premium appearance that stands apart from glossier competitors.

What Iva Pak Stick Pack Rollstock Delivers on Your Line

You need stick pack rollstock that runs cleanly, seals consistently, and represents your brand at every impression. Here is what Iva Pak engineered into every roll.

Seals That Hold at Every Impression

Consistent fin seal and lap seal performance across every roll, with tight tolerances that minimize material waste and keep your filling line running without interruption.

Converted to Your Co-Packer’s Exact Requirements

Film precision-converted to your co-packer’s specifications — unwind direction, seal type, and outer diameter — so your rollstock runs cleanly on the first pass without any adjustment at the line.

Barrier That Keeps Every Serving Fresh

Optimized oxygen and moisture barriers keep contents dry, potent, and stable from production through the consumer’s hands — critical for powders, supplements, drink mixes, and single-serve portions.

Sized to Your Exact Fill Weight

Precisely dimensioned to your product fill weight and dimensions — eliminating overfill, reducing material waste, and ensuring a consistent consumer experience across every single unit produced.

Brand Consistency Across Every Single Roll

High-definition digital printing with tight color tolerance for a consistent brand appearance across every impression and every reorder — with no plate fees and no color drift between runs.

A Sustainable Path for Single-Serve Format

Recyclable PE and PCR film options available for brands with environmental commitments — without sacrificing the barrier performance or print quality your product and line depend on.

Choose the Rollstock Format for Your Production Line

Iva Pak rollstock is compatible with a wide range of FFS equipment configurations. Here are the three most common finished-package formats our rollstock is used to produce.

Pillow Pouches

The most widely used rollstock format in the industry. A clean, cost-effective structure that runs efficiently on vertical FFS equipment — ideal for single-serve snacks, sachets, sample packs, and portion-controlled products across food and supplement categories.

Lay Flat Pouches

A flat, sealed pouch format produced from rollstock on form-fill-seal equipment. Well-suited for products sold online, displayed in bins, or packed in display boxes. Saves shipping space and works particularly well for powders, tablets, capsules, and smaller fill volumes.

Packets & Sachets

Small-format, single-serve structures for condiments, supplements, product samples, and on-the-go applications. Available in a wide range of sizes with fin seal or lap seal configurations to match your equipment and product requirements.

Why Consumers Love the Stick Pack Format

The stick pack format is not just operationally efficient — it is a consumer experience that drives loyalty, repeat purchase, and brand advocacy. Here is why your customers will love it.

Takes Up Minimal Space

Stick packs occupy a fraction of the shelf and storage space of bulkier single-serve alternatives — giving retailers a compelling stocking proposition and consumers a tidier experience at home and on the go.

Built for Life on the Move

The slender, lightweight profile fits easily into gym bags, travel kits, desk drawers, and pockets — making stick packs the natural choice for active consumers, frequent travelers, and on-the-go lifestyles.

Reduces Product Waste Per Serving

Single-serve portioning means consumers use exactly what they need — no over-scooping, no spillage, no product degradation from repeated exposure to air. Less waste per serving, better product experience every time.

Every Serving Tastes the Same

With each portion individually sealed, the contents inside every stick pack remain fresh and uncontaminated from production to consumption — delivering a consistent sensory experience your consumers can rely on.

Stick Pack Dimensions — Standard and Custom

Stick packs are available across seven standard width options and a range of lengths to match your fill weight and product dimensions. All orders can be custom-sized to your exact specifications — our team will help you identify the right dimensions based on your product and FFS equipment requirements.

Specification
Available Range
Width
20mm to 45mm (7 standard options)
Length
60mm to 200mm
Seal Type
Fin seal or lap seal
Core Size
3-inch or 6-inch
Ordering Method
Custom inquiry — quote required
Turnaround
10 business days from artwork approval

The Film That Protects Your Product and Tells Your Brand's Story

The film inside your stick pack rollstock is more than a barrier — it is the canvas your brand is printed on and the material standing between your product and everything that degrades it. Choose the structure that matches your product, your line, and your brand values.

Film Type
Barrier Level
Finish Options
Best For
MET PET
Ultra-High
Gloss, Soft Touch Matte
Food, herbs, coffee, nutraceuticals
MET BOPP
High
Gloss, Matte
Supplements, powders, dry goods
ALOX BOPP
High
Matte
Oxygen or moisture-sensitive products
PE / PE
Medium
Matte, Transparent
Recyclable packaging applications
PCR Film
Variable
Gloss, Matte
Sustainable packaging requirements

Premium Materials for Every Application

We source only the highest-quality laminated films to ensure outstanding barrier performance, print quality, and product safety.

PET/PE Laminate

Excellent clarity, puncture resistance, and moisture barrier — the most popular choice for food, snacks, and dry goods packaging.

Foil Laminate (Mylar)

Maximum barrier protection against moisture, oxygen, and light — perfect for long shelf-life products.

Kraft Paper

Natural, rustic aesthetic with strong eco-appeal — ideal for organic, artisan, and sustainable brands.

Compostable Film

Bio-based and certified compostable — for brands leading the way in sustainable packaging and circular economy.

Why Rollstock Is the Right Production Format for Stick Packs

Stick packs are exclusively produced from rollstock on FFS machinery — and the production advantages of that format compound with every run you complete.

Gets Your Product to Market Faster

Iva Pak stick pack rollstock ships in as little as 10 business days after artwork approval — keeping your launch timeline on track and your line supplied without unnecessary delays.

Lower Material Cost Per Unit

Rollstock reduces per-unit material costs compared to pre-formed packaging formats — with minimal waste in the forming process and efficient use of film from impression one to the last.

Uniform Quality Across Every Impression

Our digital printing process maintains consistent color tolerance and seal quality throughout every run — from a 5,000-impression test batch to a 500,000-impression national launch.

Run What You Need, When You Need It

Low minimum order quantities and on-demand reordering mean you only produce the volume your business actually needs right now — no over-ordering, no dead stock sitting in a warehouse.

Why Brands Choose Iva Pak

A Process That Just Works

Start Small, Scale Fast

Fast Production, Every Time

Eco-Friendly Paths Available

Premium Quality at the Right Price

Trusted by Hundreds of Brands Worldwide

Sustainable Stick Pack Film That Protects Your Product and the Planet

Iva Pak’s commitment to sustainability starts in the production process — our digital printing already uses less energy and produces less waste than traditional flexographic printing methods. Our sustainable film options extend that commitment to the material itself.

Recyclable PE Film Stick Packs

PE-based rollstock film that qualifies for store drop-off recycling programs — full barrier performance included. Available with How2Recycle labeling so your consumers know exactly what to do with the stick pack after use.

Post-Consumer Recycled Content

Stick pack rollstock produced with verified post-consumer recycled film — material recovered from consumer packaging including bottles and household plastics. Every roll reduces the virgin plastic your brand puts into the supply chain.

Our Ongoing Sustainability Commitment

Recyclable films are the starting point, not the ceiling. Iva Pak is actively developing compostable stick pack film options and continuing to invest in production innovations that reduce total packaging waste and support circular packaging goals.

Packaging With Purpose

Every sustainable choice you make with Iva Pak helps reduce plastic waste and supports a healthier planet for future generations.

Sustainable Lay Flat Pouch Options

At Iva Pak, we believe great packaging doesn’t have to come at the planet’s expense. We offer a full range of sustainable lay flat pouch options that reduce environmental footprint without compromising performance.

Compostable Films

Certified home and industrial compostable materials that break down naturally without leaving harmful residue.

Recyclable Mono-Materials

PE and PP mono-material structures fully compatible with existing recycling streams — no separation required.

Lightweight Design

Lay flat pouches use significantly less material than rigid packaging, reducing overall waste throughout the supply chain.

Explore Eco Options

From Inquiry to Stick Pack Rollstock on Your Line — Four Steps

Getting your custom stick pack rollstock from Iva Pak is a clear, four-step process. Here is what to expect from first contact to delivery.

1

Submit Your Requirements

Tell us your product type, fill weight, target dimensions, equipment or co-packer specifications, and required volumes. We respond within 24 hours with a quote tailored to your line.

Get Your Artwork Approved

Send your brand design to our pre-press team. We prepare a digital proof for your sign-off — confirming color accuracy, print registration, and layout across the full narrow format before production begins.

2

3

Production and Roll Conversion

Artwork approved — production starts. Film is printed and precision-converted to your exact roll specifications in as little as 10 business days. No plate fees. No unnecessary delays.

Your Rollstock Is on Its Way

Rolls are packed for safe transit and dispatched to your facility or directly to your co-packer. Your line is ready to run from the moment your Iva Pak rollstock arrives.

4

Stick Pack Packaging Questions — Answered

Have a specific question about your dimensions, film requirements, or co-packer specs? Our team responds within 24 hours.

Stick pack packaging is a narrow, elongated single-serve flexible packaging format produced from rollstock on form-fill-seal (FFS) machinery. Products are measured and dispensed into individual stick packs — each sealed at the top and bottom — creating a compact, portable, single-use package. The format is widely used for powdered supplements, drink mixes, instant coffee, sugar, condiments, and pharmaceutical products.

Stick packs and sachets are both single-serve FFS formats, but they differ primarily in shape and intended use. Stick packs are narrow and elongated — typically 20mm to 45mm wide and 60mm to 200mm tall — designed to be torn open at one end and poured into a drink or mouth directly. Sachets are generally wider and shorter, suited for condiments, wet products, and samples. Stick packs are the format of choice when portability and precision dosing are the primary requirements.

Iva Pak offers stick pack rollstock in seven standard width options from 20mm to 45mm, with lengths from 60mm to 200mm. All dimensions can be customized to your exact fill weight and product requirements. Our team will help you identify the right dimensions based on your product and FFS machine specifications.

We offer both fin seal and lap seal configurations for stick pack rollstock. Fin seal creates a standing seam along the back of the stick pack — the most common option. Lap seal creates a flat, low-profile back seam. The right seal type depends on your product, your equipment specifications, and your desired finished-pack appearance.

Yes — this is one of the most common scenarios we work with. Share your co-packer’s exact film requirements — seal type, unwind direction, maximum outer diameter, and core size — and we will precision-convert the rollstock to match their equipment exactly, so it runs cleanly from the very first impression.

We offer MET PET (ultra-high barrier), standard PET (high barrier, excellent clarity), BOPP (high barrier, dry goods), PE/PE (recyclable), and PCR film (post-consumer recycled content). Additional options include specialty laminates, metalized PET and foil, freezer-safe films, and microwaveable films. Our team will recommend the right film for your product’s barrier requirements and shelf life.

Yes. All films, inks, and adhesives used in Iva Pak’s stick pack rollstock comply with FDA food contact regulations. We use water-based inks and food-safe laminating adhesives. Our manufacturing processes follow strict quality control standards to ensure every roll that leaves our facility is safe for direct food contact applications.

Ready to Launch Your Single-Serve Stick Pack? Let's Get Started.

Request your custom quote for stick pack rollstock from Iva Pak today. Tell us your product, your dimensions, your fill weight, and your production requirements — and our team will come back to you within 24 hours with pricing and a solution built for your line.

Request a Quote for Custom Stick Pack Packaging

Fill in the details below and one of our stick pack specialists will respond within 24 hours with pricing and specifications for your product and line.