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Custom High Barrier Stick Packs and Back Seal Bags
Launch your single-serve powder product with packaging that fits your production setup. Cailyn supplies both premade back seal stick bags for smaller filling operations and printed rollstock films for compatible automatic packaging lines.
With finished bag widths down to 3.5 cm, digital printing from 100 pieces, and gravure printing in up to 10 colors, we help brands develop compact packaging for single-cup coffee, energy drink mixes, electrolyte powders and other powdered beverages.
Complete your product range with matching retail cartons, gift boxes and filter bags from one packaging partner.
Custom Powder Stick Packs and Rollstock — Widths Down to 3.5 cm, Digital Printing from 100 Bags
Two Packaging Formats for Different Production Needs
Premade Stick Bags: Fill, Seal and Start Small
Developing a new powder product does not always require investing in an automatic stick-pack machine.
Our premade back seal bags arrive with the pouch body formed and a filling opening left unsealed. Fill the powder through the opening, then heat-seal it using equipment suitable for the selected material.
This format is a flexible option for:
- New product launches and trial batches
- Small-volume production
- Multiple flavors or artwork versions
- Promotional samples and tasting kits
- Brands assessing demand before expanding production
Premade bags reduce the need for on-site bag-forming equipment. Filling accuracy, a clean sealing area and appropriate heat-sealing settings still need to be established for your product.
Printed Rollstock: For Automatic Forming and Filling
For customers operating automatic packaging equipment, we also supply custom printed rollstock film.
Your machine forms the film into bags, fills the powder and seals each pack. We confirm the film specification around your equipment requirements, including web width, print repeat, registration marks, winding direction and sealing compatibility.
Start with premade bags for development, or choose rollstock when your production setup supports automatic forming and filling.
Slim Stick Packs with Widths Down to 3.5 cm
A narrow stick pack offers a compact presentation for a measured portion of powder. It fits easily into retail boxes, sample kits and travel packs, while providing a convenient format for single-cup preparation.
Cailyn can produce finished back seal bags with widths down to 3.5 cm, with length selected according to the product and filling requirements.
Bag size should be based on powder bulk density and filling behavior—not weight alone. Send us your serving size and product details so we can help evaluate suitable dimensions.
Material Options for Different Protection Goals
Powders vary in their sensitivity to moisture, oxygen and light. We offer several material routes, selected around your formulation, storage conditions and target shelf life.
Metallized Films
Metallized film structures provide a metallic appearance and barrier options for suitable powder applications.
They can be evaluated for instant coffee, drink mixes and other dry products where the chosen laminate meets the required protection level.
Aluminum Foil Laminates
For products with demanding protection requirements, aluminum foil laminates are an option to evaluate for moisture, oxygen and light protection.
Aluminum foil and metallized films are different materials. We can help you compare them according to the product’s sensitivity, packaging format and budget.
EVOH Barrier Structures
EVOH-containing structures offer another route when oxygen protection is a priority. The surrounding layers must also be selected for moisture protection, sealing and the intended storage environment.
The complete laminate determines performance; the presence of EVOH alone does not establish the bag’s suitability for every powder product.
NK / PLA Options
NK/PLA structures are available for projects exploring cellulose-based films and PLA sealing layers with compostability goals.
We review the specific material grades, barrier requirements and finished-pack specification before recommending this option. Biodegradability or compostability claims must be supported for the finished packaging under defined conditions.
PE/PE Options
PE/PE structures provide a mono-material-family route for projects targeting recyclability.
They should be evaluated against the product’s protection requirements. Actual recyclability depends on the complete construction and the collection and recycling systems available in the destination market.
| Material Route | Main Consideration |
| Metallized Film Laminate | Metallic appearance with barrier performance selected for the application |
| Aluminum Foil Laminate | An option for demanding moisture, oxygen and light protection needs |
| EVOH-Containing Structure | Oxygen barrier combined with suitable protective and sealing layers |
| NK / PLA | A material route for projects with compostability goals |
| PE / PE | A mono-material-family route for projects targeting recyclability |
Flexible Printing for Launches and Larger Orders
Digital Printing from 100 Pieces
Our digital printing option starts from 100 premade bags, making it easier to develop custom packaging without committing to a large initial inventory.
It is suitable for exploring new flavors, testing artwork and preparing branded samples. Digital printing does not require gravure cylinders, helping simplify the setup for smaller projects.
The applicable MOQ is confirmed against the selected material, dimensions and number of designs.
Gravure Printing in Up to 10 Colors
For larger production runs, Cailyn offers gravure printing in up to 10 colors.
We review your artwork, white ink requirements and any spot colors to establish the printing specification. Both premade bags and rollstock projects can be discussed according to the material and production requirements.
Single-Serve Packaging for Everyday Use
Single-Cup Coffee
Compact sachets for instant coffee or coffee drink mixes, with dimensions matched to the intended serving.
Energy and Pre-Workout Drink Mixes
Portable powder packs for measured servings prepared with water.
Electrolyte and Hydration Powders
Slim packaging for travel, exercise and everyday drink preparation.
Tea and Flavored Beverage Powders
Custom packs for powdered tea, fruit-flavored mixes and other instant beverages.
Other Dry Blends
Back seal bags can also be evaluated for sweeteners, seasonings and other portioned powders.
Matching Boxes, Gift Packaging and Filter Bags
The individual stick pack is only one part of the customer’s experience. Cailyn can also produce matching retail cartons, gift boxes and filter bags for related coffee or tea product ranges.
We can develop the outer packaging around your actual stick dimensions and preferred pack count, helping the components work together from the start.
Coordinating these items through one supplier can simplify artwork communication, reduce separate sourcing work and support consolidated shipping. Packing arrangements and freight savings depend on the final order.
Product Specifications
| Item | Available Options |
| Product Format | Premade back seal stick bags and printed rollstock |
| Finished Bag Width | Down to 3.5 cm to 30cm |
| Bag Length | Customized according to serving size and filling requirements |
| Material Options | Metallized film, aluminum foil, EVOH-containing structures, NK/PLA and PE/PE |
| Digital Printing MOQ | From 100 premade bags, subject to specification |
| Gravure Printing | Up to 10 colors |
| Filling Method | Manual or assisted filling for premade bags; compatible automatic equipment for rollstock |
| Final Closure | Heat sealing with settings matched to the material |
| Matching Packaging | Retail cartons, gift boxes and filter bags |
| Main Applications | Coffee, energy drink mixes, hydration powders and other dry blends |
Frequently Asked Questions
Do I need an automatic stick-pack machine?
Not for the premade bag option. You can fill the prepared bags and close the remaining opening with suitable heat-sealing equipment. Your process still needs to provide accurate filling and reliable seals.
Can you supply film for my existing packaging machine?
Yes. Send us your machine’s film requirements, bag dimensions and sealing configuration so we can review a suitable rollstock specification.
Can you make a narrow bag for a small serving?
Yes. Finished bag widths can be as narrow as 3.5 cm. We confirm the length and filling opening according to your powder’s volume and the filling method.
Are metallized bags the same as aluminum foil bags?
No. They use different barrier materials. We can compare suitable constructions based on the protection your product needs.
Can I start with 100 custom printed bags?
Yes. Digital printing starts from 100 premade bags for supported specifications. Please provide your material preference, dimensions, quantity and artwork count for confirmation.
Can you supply the retail box as well?
Yes. We can develop matching cartons or gift boxes around your stick packs, including different pack counts and artwork designs.
Start Your Custom Powder Packaging Project
Tell us your product type, serving weight, target shelf life, preferred bag dimensions and order quantity. Let us know whether you need premade bags or rollstock, and whether the project includes retail boxes or other packaging components.
Contact Cailyn for samples, material options and a coordinated packaging quotation.
