THE SLIM STICK
23 × 110 mm
A starting point for smaller servings. The template’s planning range is 1–6 g; a light, bulky powder may need more room.
- Flat template width
- 56 mm
THE PACKAGING STUDIO
Stick pack film &
retail packaging.
Your product.
Ready to make
an impression.
The powder is part of the story. The package is what your customer holds. Let’s bring the stick, the artwork, and the retail format together.
Made to look right.Specified to run right.
01 / EXPLORE THE FORMAT
Same stick.
A different presentation.
Explore how your servings come together. These concepts help start the conversation; your final packaging is confirmed around your product.
01
One serving. Its own package.
The stick film holds your powder. Start with the actual blend, fill weight, and material requirements before settling on a size or ordering printed film.
- Materials to plan
- Suitable stick film, approved production artwork, and an agreed shipping packout.
- What we confirm
- Film dimensions, barrier needs, seal requirements, artwork orientation, and each SKU’s quantity.
02
A collection of servings. Ready to present.
A retail carton brings individual sticks together. Decide how many servings belong in each box, then confirm the structure around the actual filled sticks.
- Materials to plan
- Stick film plus the agreed carton and any inserts or additional components.
- What we confirm
- Sticks per box, carton dimensions, assembly, flavor assortment, and final packout.
03
Your sticks. Together in a pouch.
A retail pouch holds a set of individually sealed sticks. It is a secondary package here—not loose powder filled directly into a pouch.
- Materials to plan
- Stick film plus a suitable retail pouch and any separately agreed components.
- What we confirm
- Sticks per pouch, usable dimensions, closure, flavor assortment, and final packout.
Exploring a format does not add services or materials to your estimate.
02 / FIND YOUR FIT
Small package.
Room for the right blend.
Start with the dimensions. Then let’s confirm how your actual powder fits. A gram of one blend can take up very different space from a gram of another.
Finished stick width × length · diagrams show relative proportions, not actual screen size.
Need a different length?
We can review longer 23 mm sticks, up to 140 mm, and custom lengths in the 35 mm width. The right length depends on your powder and serving size. Ask for a project-specific dieline rather than stretching a standard template.
Help me choose a sizeBefore you design or print.
These are blank reference templates. The flat film is wider than the finished stick because it wraps around and seals. Keep the PDF dimensions intact, and confirm the final dieline, film specification, artwork orientation, and print proof with us before ordering.
Retail boxes and pouches need their own dielines, sized around the filled sticks and your chosen pack count.
03 / WHO BRINGS WHAT?
Your materials.
Or our help sourcing them.
Either way, we agree the specifications first. Materials and manufacturing are separate parts of your quote.
Already have a packaging partner?
Bring suitable stick film and retail materials. We review the specifications and receiving requirements before you buy or ship anything.
- Confirm film specifications and approved artwork
- Include boxes, pouches, and other agreed components
- Define the quantities and packout for each SKU
Need help putting it together?
Select StickPax-supplied packaging in the full quote. Add retail packaging materials explicitly if you need them, then we’ll confirm the actual project requirements.
- Film and retail packaging are distinct material costs
- Directional allowances include a 10% buffer
- Final specifications and purchasing minimums affect cost
Ingredients and flavors are separate too. Developing the formula? Want blank-stick samples of your supplied blend?
04 / BEFORE YOU PRESS PRINT
Great artwork.
The right specifications.
A beautiful mockup is a starting point. Production needs confirmed dimensions, material requirements, and approved files.
Don’t order film on grams alone.
See how manufacturing comes togetherThe same fill weight can take up different amounts of space. Confirm the actual powder and package together.
Start with the powder.
Share the actual formula or finished blend, target fill weight, and intended presentation. Grams alone don’t tell us how much space the powder needs.
Confirm the specifications.
Agree the stick dimensions, material and barrier requirements, and retail format. Use the confirmed dieline—not a visual mockup—to prepare production artwork.
Review the artwork.
Provide production files, final copy, flavor versions, color requirements, orientation, and any coding needs. Confirm the approval process before printing.
Order the right materials.
Agree who purchases film and retail packaging, quantities, purchasing minimums, and timing. Hold off on printed stock until specifications and artwork are confirmed.
Define the finished packout.
Confirm sticks per retail unit, quantities per flavor, any mixed assortment, inserts, and shipping arrangement. The finished goods should match the agreed scope.
05 / CONNECT THE FORMAT TO THE NUMBERS
Plan your run.
Picture your inventory.
Your total sticks drive the manufacturing estimate. Your sticks per retail pack determine how those servings come together.
YOUR RETAIL PACKOUTOne SKU
250complete boxes of 30
No sticks remaining at this pack size.
Counts only—not a packaging price. Flavor splits and final packout need confirmation. Choose who supplies materials in the full quote; your pack-size selection carries with you.
Need another pack size or assortment?Labor here. Materials in the full quote.
The glass calculator shows tolling only: blending, filling and sealing, and agreed retail packout for one SKU. You supply ingredients and packaging at this stage.
Choose packaging supply and any additional services in the full quote. Changing the format or pack size here does not add a packaging charge.
Online estimates cover 7,500–100,000 sticks at 1–12 g. Volume pricing starts above 25,000. Smaller runs and other fills need a custom quote.
YOUR RUN, ESTIMATED8 g fill
What will your run cost?
Estimated starter tollingUSD
7,500 sticks · 8 g each$0.73 / stick
7,500 sticks at 8 grams: $5,500, $0.73 per stick.Tolling only · one formula / flavor.
You supply ingredients and packaging.
Starter runs
Volume pricing Above 25,000
Enter a whole number from 7,500 to 100,000 sticks.
Tolling only · 8 g fill. Includes blending, filling and retail packout. You supply ingredients and packaging. Materials and additional services cost extra. Displayed prices are rounded estimates.
What does this estimate include?
Blending, filling/sealing and retail packout for one formula or flavor at your selected 8 g fill. Estimate any quantity from 7,500 to 100,000 sticks; volume pricing begins above 25,000. You supply suitable ingredients, stick film and retail packaging. Powder analysis, blank-stick samples, formulation, sourcing, testing, freight and taxes are excluded. Configure your full quote to add SKUs / flavors at $400 for each one after the first. Your complete quote confirms the scope.
Below 25,000 total sticks, you supply all production ingredients and the complete flavor system. Ingredient sourcing is available by separate quote at 25,000+ total sticks across all SKUs / flavors, subject to formula review and supplier requirements. Packaging sourcing and formulation sample development remain available for smaller runs.
GET CLEAR BEFORE YOU START
The details behind the package.
Can I supply my own printed stick film?
Yes, suitable customer-supplied film can be reviewed for your project. Confirm the material, dimensions, roll and artwork specifications before purchasing or shipping it. A design mockup alone does not confirm that film is ready for production.
What size should my stick pack be?
Our standard reference templates are 23 × 110 mm and 35 × 105 mm (finished width × length). A 35 × 140 mm template is also available for a taller option. We review the actual powder and target fill: two blends at the same weight can occupy different volumes. Density, flow, seal space, and material requirements inform the final dimensions. Don’t order film based only on the grams shown in the calculator.
Can I download a stick pack dieline?
Yes. The size guide on this page includes blank PDF templates for 23 × 110 mm, 35 × 105 mm, and 35 × 140 mm sticks. They are reference files for planning. Confirm the project-specific dieline and print specifications before ordering film; don’t resize a template to create a new length. Retail boxes and pouches require separate dielines.
Can StickPax supply boxes or pouches?
We can help scope suitable retail packaging for sticks. Choose StickPax-supplied packaging in the full quote and explicitly add retail packaging materials if needed. Final format, dimensions, closures, purchasing minimums, and availability need confirmation.
Does tolling include packaging materials?
No. The tolling estimate covers blending, filling and sealing, and agreed retail packout labor for one formula or flavor. Printed stick film, boxes, pouches, inserts, and other materials must be supplied or quoted separately.
How are packaging costs estimated?
The full quote uses directional allowances for StickPax-supplied packaging, including a 10% buffer. Specifications, finishes, artwork, material minimums, and retail format can change the final price. The calculator on this page shows tolling only.
What happens if my quantity doesn’t divide into full retail packs?
The planner shows complete packs and remaining sticks separately. Agree whether to adjust the quantity or how to handle the remainder. When retail packaging is selected in the full quote, its allowance includes one additional package for a remainder; that does not establish an approved retail packout.
Can I combine flavors in the same box or pouch?
Tell us the exact assortment and quantity of each flavor so we can review the packout. The planner assumes one SKU. The manufacturing quote uses total sticks across the order and adds $400 for each SKU or flavor after the first; assortments and split quantities still need confirmation.
Do you develop the formula or make blank-stick samples?
Custom formulation and optional powder analysis are separate services. Formulation develops the recipe. Powder analysis evaluates a customer-supplied blend and includes preproduction samples in blank sticks. Neither is automatically added by choosing a packaging format.
LET’S PUT IT TOGETHER
Something they’ll hold.
Something you’ll be proud of.
Tell us about your powder, your packaging direction, and the run you have in mind. We’ll help define what needs to happen before anything gets printed.
Configure full quote Choose your scope. Download your estimate. Send it to us.