Stick packs are one of the most convenient and popular formats for RTM beverage powders. But achieving perfect, consistent packaging requires precision and expertise. In this post, we’ll explore the most common stick pack filling and powder packaging issues, and how GRAMS Inc. addresses them.
Common Stick Pack Challenges
1. Powder Flow Problems
- Cause: Fine powders, moisture, or static electricity can cause clumping or bridging in hoppers.
- Solution: GRAMS uses flow aids, dehumidification, and equipment designed for consistent feeding.
2. Fill Weight Inconsistency
- Cause: Poor calibration or irregular powder density.
- Solution: Our automated filling systems are routinely calibrated, with in-line weight checks for every run.
3. Seal Failures
- Cause: Incorrect heat settings, film incompatibility, or powder contamination on sealing jaws.
- Solution: We use high-quality films, strict seal monitoring, and cleaning protocols to ensure reliable closure.
4. Powder Dusting & Contamination Risk
- Cause: Fine powder escaping during filling.
- Solution: Dust extraction systems and controlled environments keep packaging clean and compliant.
5. Moisture Absorption & Caking
- Cause: Hygroscopic ingredients (like salts and sugars) absorb humidity.
- Solution: Climate-controlled rooms and moisture-resistant films preserve powder flowability.
Why Stick Pack Quality Matters
- Consumer experience: Easy tear, clean pour, smooth dissolution.
- Shelf life: Proper seals prevent oxygen and moisture ingress.
- Regulatory compliance: Fill weights and label claims must match actual product.
GRAMS Inc.’s Approach
- Precision equipment designed for powders with varying particle sizes.
- Film selection support to match formula characteristics.
- Ongoing QC checks, including seal integrity and fill weight verification.
- Operator expertise — skilled technicians who know how to adjust settings to prevent downtime.
Final Thoughts
Stick pack filling isn’t just about packaging — it’s about preserving quality and delivering a consistent consumer experience. At GRAMS Inc., our troubleshooting expertise ensures every stick pack is reliable, compliant, and consumer-ready.
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