Custom Electrolyte Stick Packs
An electrolyte stick is a tiny package with a big job: it has to pour into a bottle neck one-handed, survive a gym bag, and carry a mineral panel down a strip of film about an inch wide.
Skip the blank page
You already know what you are packaging, so there is nothing to set up. This opens the design engine with the stick pack structures on screen — then you type your own dimensions and the dieline is generated at that exact size.
The structures electrolyte stick packs actually ship in
Every one of these is a construction TWOFORM generates a real production dieline for, at your own dimensions — not a template you have to fit your product into. Each opens the engine already on that package type.
Settle this before you design
Fill weight picks the lane, and the lane is the width
Stick machines run fixed lane widths — around 17, 23, 28, 35, 40, 45 and 50mm — over lengths of about 50 to 170mm. A 5 to 8 g electrolyte dose lands naturally at 23 × 110mm, and a heavier mineral blend at 35 × 130mm. Choose the lane your fill sits in, then design to that exact width rather than to a size you would prefer.
The mistake that costs a print run
Designing a flavour range that only works flat
Sticks are seen edge-on in a box, in a drawer and in a gym bag, so what identifies the flavour has to work on a one-inch-wide strip viewed from the side. Ranges built around a large front-panel illustration become indistinguishable in use. Put a strong colour block and the flavour name where they read on the narrow face.
How you actually make it
- Open the structure above and type your real dimensions. The dieline is generated at that exact size and validated against real manufacturing limits as it draws — if a size cannot be folded, glued and shipped, it says so before you design anything on it.
- Describe your brand and the AI designs the artwork directly onto that dieline — not onto a picture of a package.
- Place your own logo, barcode and any required panel yourself. The AI leaves them exactly as placed unless you ask it to change them.
- Fold it in live 3D to check it, then download print-ready files to use with any printer — or have TWOFORM manufacture it.
Questions about custom electrolyte stick packs
What size stick pack suits an electrolyte serving?
A 5 to 8 g dose usually runs at 23 × 110mm; heavier blends move to 35 × 130mm. The fill weight picks the machine lane, and the lane fixes the width.
How much can I print on a stick pack?
Less than the flat width suggests. The tube curves and there is a seam down the back, so plan on a readable column of roughly half to two-thirds of the flat width.
Do I need a carton for retail sticks?
For a shelf, yes — a single stick has no room for a compliant ingredient panel or a barcode. Direct-to-consumer counts often use a resealable bag instead, which survives shipping better.