4-Lane Stick Pack Packaging Solution for Orange Electrolyte Powder / Oral Rehydration Salts

Project Overview

Customer Requirement

The customer from the United States required a compact but efficient stick pack solution for small-dose powder products. For products such as orange electrolyte powder and oral rehydration salts, the customer needed stable dosing, clean sealing, easy-tear stick packs, and a reliable production speed.

The machine was designed for a 2–6g filling range, which is suitable for many functional powder products, including:

• Orange electrolyte powder

• Oral rehydration salts

• Vitamin drink powder

• Sports hydration powder

• Mineral supplement powder

• Functional beverage powder

• Pharmacy single-dose powder products

To improve production capacity, the customer purchased 2 sets of the same 4-lane machine.

Why Stick Pack Is Suitable for Electrolyte Powder / ORS

Electrolyte powder and oral rehydration salts are usually packed as single-serving products. Stick pack packaging is especially suitable because it is lightweight, portable, easy to tear, and convenient for consumers to mix with water.

For the U.S. health and nutrition market, stick packs are widely used in:

• pharmacy and healthcare channels

• sports nutrition products

• travel hydration products

• emergency rehydration products

• outdoor and fitness products

• contract packaging projects

Compared with wider sachet bags, stick packs use less packaging film and are easier to count, box, or carton in secondary packaging.

Machine Solution for This USA Project

For this project, Samfull supplied SF-520 4-lane back-seal stick pack packaging machines.

The machine uses volumetric cup dosing, which is suitable for small-dose free-flowing powder or granular powder products. For electrolyte powder and oral rehydration salts, the dosing system needs to maintain stable filling while avoiding material shortage during continuous operation.

The production order also required a hopper material level sensing switch. This is useful for powder stick pack production because it helps remind operators when the material level is low, reducing the risk of empty filling or unstable dosing.

Production Capacity

The confirmed speed is 43 cuts per minute.

Because this is a 4-lane machine, the theoretical capacity of one machine is:

4 lanes × 43 cuts/min = approx. 172 stick packs/min

The customer ordered 2 sets, so the total theoretical capacity is:

172 packs/min × 2 machines = approx. 344 stick packs/min

This capacity is suitable for medium-to-large scale production of electrolyte powder stick packs, oral rehydration salts stick packs, and other small-dose health powder products.

Packaging Details

The final stick pack size is compact and suitable for 2–6g powder filling.

For electrolyte powder and oral rehydration salts, moisture protection is important. Composite film or paper-aluminum laminated film helps improve barrier performance and supports better product protection during storage, transport, and retail distribution.

Quality Control Requirement

According to the production order, the qualification standard is:

Only 3 unqualified packs are allowed per 1000 packs.

This quality requirement is important for small-dose stick pack production because each pack must maintain stable appearance, sealing, cutting, and filling performance. For health-related powder products, packaging consistency directly affects brand reliability and customer experience.

Key quality control points include:

• stable small-dose filling

• smooth powder feeding

• neat back sealing

• accurate bag length control

• clean cutting edge

• reliable easy-tear effect

• stable multi-lane operation

• reduced empty-pack risk through material level sensing

Why This Case Is Valuable for Similar Customers

This U.S. case shows a practical solution for companies that need a reliable electrolyte powder stick pack packaging machine or oral rehydration salts stick pack machine.

The solution is especially suitable for:

• health product manufacturers

• sports nutrition brands

• pharmacy product suppliers

• oral rehydration salts producers

• beverage powder factories

• contract packaging companies

• private label powder brands

With 4-lane output, 43 cuts/min speed, 2–6g filling range, Siemens control system, and 304 stainless steel frame, this project provides a balanced solution between production efficiency, machine cost, and long-term operation stability.

Conclusion

This United States customer case demonstrates Samfull’s practical experience in small-dose stick pack packaging for functional powder products.

The customer selected 2 sets of SF-520 4-lane stick pack packaging machines for orange electrolyte powder / oral rehydration salts applications. With 43 cuts/min speed, each machine can reach about 172 packs/min, and the two-machine solution can reach about 344 packs/min.

For customers looking for a reliable solution for electrolyte powder stick pack packaging, oral rehydration salts stick pack packaging, or 2–6g health powder stick pack production, this case provides a clear reference.