Everything your designer needs to create print-ready artwork for stick pack packaging — dimensions, zones, file specs, and common mistakes to avoid.
✓ Die cut included✓ AI · PDF · EPS formats✓ For designers & clients
01 · Overview
What is a stick pack?
A stick pack is a narrow vertical pouch made from laminated film, filled with powder and sealed on three sides. It's single-serve, portable, and keeps dosing precise from batch to batch.
The width is fixed by our production equipment. The height adjusts based on your formula's serving size and density. Final dimensions are confirmed after formula sign-off.
Width
36 mm
Fixed · production standard
Height
Varies
Set by serving size & formula
Finish
Gloss / Matte
Confirmed at order stage
Important: Do not start designing until you receive the confirmed die cut file from ASAP Nutrition. Dimensions change based on your exact formula and serving size.
02 · Die Cut Template
Download & use the template
The die cut defines exactly where your design can be placed. It includes the printable area, seal zones, and cut lines. Your designer must work within these boundaries — artwork outside them will be cut off or sealed over.
Stick Pack Die Cut Template
ZIP archive · includes AI, PDF, EPS · updated 2025
Heat-sealed shut. Leave empty or use background only
✗ No
Side seals
~4 mm each side
Film folds and seals here. No text or logos
✗ No
Bleed
3 mm outside cut line
Background color only — gets trimmed in production
Background only
03 · Design Layout
Where to place key information
The stick pack is narrow and vertical. Prioritize information by visual weight — the most important element should read at a glance from 50 cm away.
Position
Recommended content
Priority
Top 1/3
Brand logo, product name — largest element on pack
High
Middle 1/3
Flavor, variant, hero ingredient or key claim
High
Bottom 1/3
Net weight, "per stick" callout, legal line
Medium
Back side
Supplement facts, ingredients, warnings, barcode
Required
Do
Keep brand name and logo in the top third
Use large type — minimum 7pt for body text
Extend background color to bleed edges
Keep all critical text inside the safe zone
Use high-contrast colors on narrow elements
Submit design as vector (AI or PDF) with fonts outlined
Don't
Place logos or text inside seal zones
Use raster images below 300 DPI
Leave background white — it shows at cut edges
Submit Photoshop or Canva files as final artwork
Place text too close to side edges
Use thin strokes — they disappear on film
04 · Roll Layout
How your design repeats on the production roll
During production, stick packs are filled from a continuous film roll. Your design repeats across this roll — orientation and repeat distance (pitch) must be correct or every pack will print wrong.
1
Stick layout on roll
Your design is tiled horizontally across the roll width. Confirm with ASAP how many columns fit your roll — typically 1 or 2 sticks wide depending on equipment.
2
Film direction
The film unrolls from bottom to top. Your design must be oriented so it reads correctly in this direction. If rotated, every pack prints upside down. Mark "top of pack" clearly in your file.
3
Repeat / pitch
The distance between each stick on the roll is the "pitch" — it equals your pack height plus the cut margin. ASAP sets this in production. Do not add extra spacing in your artwork file.
Rule: Always indicate the top of the pack in your design file. Add a note on a separate non-printing layer: "FILM DIRECTION ↑ — this side fills first." This prevents orientation errors before printing begins.
05 · File Specifications
What to send and how
Requirement
Specification
Status
File format
Adobe Illustrator (.ai) or print-ready PDF
Required
Color mode
CMYK — not RGB or Pantone unless agreed in advance
Required
Resolution
300 DPI minimum for any embedded raster images
Required
Fonts
All fonts must be outlined / converted to paths
Required
Bleed
3 mm bleed on all sides, background extends to bleed
Required
Die cut layer
Keep the die cut on a separate non-printing layer labeled "DIE CUT"
Recommended
Linked images
Embed all images — do not leave them linked externally
Required
06 · Packaging Options
How sticks are packed for delivery
Once filled and sealed, stick packs can be grouped into different outer packaging depending on your sales channel and brand positioning.
A
Sticks in a Pouch
A flexible resealable pouch containing multiple stick packs. Lightweight, cost-effective, and popular for e-commerce, subscriptions, and direct-to-consumer brands.
B
Sticks in a Box
A structured cardboard box with individual sticks. Clean retail presentation, ideal for pharmacy shelves, premium positioning, and gifting formats.
C
Custom Format
Tubular packaging, special bags, branded display boxes, or any other custom format. Contact us to discuss feasibility and minimum order quantities.
07 · FAQ
Common questions
Can I change the stick size?
Width is fixed by our equipment standard. Height is adjusted based on your formula's serving size and powder density — confirmed after formula approval.
What if I don't use the official die cut?
Artwork submitted without the official template may place text or logos in seal zones. These areas are heat-sealed during production and will be covered or distorted. Always start from the die cut file.
Can ASAP Nutrition prepare the design for me?
Yes. We offer in-house label design and printing services. Contact us with your brand assets and we can prepare production-ready artwork. Additional fees apply.
Do I need to design both sides?
Yes. The front carries your brand and product identity. The back must include supplement facts, full ingredient list, allergen warnings, net weight, and any required regulatory information.
How long does production take?
After deposit and approved artwork: 3–5 business days when ingredients are in stock. Custom formulas may require additional sourcing time. Full timeline is confirmed at order stage.
What is the minimum order quantity?
Production starts from 1,000 units per SKU. Volume pricing is available — contact us for a quote on larger orders.
Questions about your file or specs?
Our team reviews every artwork file before printing. Contact us before submitting — we'll catch issues early.