DRY PACKAGING
From powders and seasonings to drink mixes, baking blends, and special ingredients, we help food brands package dry products at scale without losing quality, control, or margins.
Lots of contract packagers run products. We're true partners in scale. Dry packaging isn't just about filling and sealing. Success requires a true understanding of how your product behaves, how it's sold, and what must go right for your brand's margins to hold.
We take the time to understand your formulation, growth stage, and distribution plan before ever quoting a run. Whether you're launching a single-serve stick pack for retail, converting hand-filled food service portions into automated production, or solving for weight variability in a powder blend, we think through the operational reality with our partners.
When you work with T.H.E.M., you're not hiring a line. You're expanding your team with expertise that cares about consistency, scalability, and protecting your brand through growth.
Types of Dry Packaging We Offer
Stick Packs Packaging
T.H.E.M. brought the stick pack to North America in 1997. Today, we're running over a billion per year in our production facilities. From 60mm wide to 190 mm long, we can work with you to determine the best package size for any dry application. These are great for "on-the-go" formats of powdered drink mixes, portion-controlled supplements, functional ingredients.
Common use cases: hydration mixes, coffee, protein, electrolyes, collagen, seasoning shots.
Pillow Pack Packaging
Vertical-type wide pillow bags can be flexibly created to run as single pouches or bandoliers, or with holes punches for shelf hanging.
Common use cases: spice blends, baking mix portions, seasoning blends, coffees, refills, and more.
Benefits of Powder and Granule Packaging
Dry packaging seems straightforward, until scale exposes the weak points. In single-serve and flexible formats, the details matter, from fill weight, to flow behavior, to seal integrity. When those variables are controlled, your product performs. When they're not, your brand's margins take the hit.
Here's what the right packaging setup does for your business.
Consistent Fill Weights & Fewer Margin Leaks
Powders and blends have their own personalities. Density shifts, flows change, and product can bridge, aerate, or settle.
As an engineering-led business, we build your packaging process around those realities so weights stay consistent and yield stays predictable. Enjoy cleaner seals, better shelf stability, and packaging that holds up from warehouse to consumer.
Packaging that Works with your Product
Some dry products flow beautifully. Others clump, dust, or react to humidity. The right film structure, sealing setup, and fill method matter. We evaluate your product characteristics before production so you're not discovering incompatibility mid-run. Nobody likes expensive surprises, least of all while your brand is scaling.
Operational Efficiency that Supports Growth
Well-designed dry packaging improves more than shelf presence and user experience. If you're vertically integrating production or consolidating vendors, the right packaging strategy simplifies your supply chain instead of complicating it. When you choose T.H.E.M. for dry packaging, you're getting a process that protects your margins, supports scale, and keeps your brand credible as you grow.
Why Brands Choose T.H.E.M. for Dry Powder & Granule Single-serve Contract Packaging
T.H.E.M. is built for brands who can't afford failure points. Here's what sets us apart:
- Zero recalls in our history - a direct result of our disciplined quality systems, in-house testing, and continuous monitoring
- Radical transparency - We evaluate the product realistically and build a process around it
- Dedicated allergen facility - For brands with strict controls, our separate facility reduces cross-contamination risk for nuts and other allergens
- Quality team embedded on the floor - Micro, weight checks, seal verification, and more... your product is monitored every step of the way
- Speed + Scalability - whether you're launching a new SKU or scaling to big-box distribution, we're built to grow with you
- Premium brand differentiation - Stand out with shapes, not just graphics. Our innovative machinery unlocks unique, ergonomic formats that customers remember
- Integrated OEM Expertise - We don't just run machines, we co-develop with Sanko, the original inventor of the stick pack, across a 25-year partnership. No other North American co-packer has this depth of insight.
- Clean seals + leak-free performance - our tooling, film expertise, and engineering validation ensure package integrity to preserve your product's reputation
Dry Packaging FAQs & Resources
What kinds of dry products do you package?
Powders, blends, seasonings, drink mixes, grains, baking mixes, personal care products, and other dry foods can be filled in flexible packaging formats.
Can you handle "difficult" formulas, like dusty, static, clumpy, or hygroscopic powders?
Yes. The right approach depends on the product's behavior. We'll work with brands up-front to determine flow rate, humidity sensitivity, particle size, and packaging needs. If you visit our facility, you can tour the pilot lab where the engineering magic happens.
Do you support both retail and food service packaging?
Absolutely. We work with brands selling DTC, retail, and food service. Packaging format and pack size should match the channel, and can support that decision process.
What's your typical minimum order quantity (MOQ)?
It depends on the format and product. Share your current volume and target channel, and we'll tell you what's realistic.
Can you help us choose between stick packs, sachets, and pillow packs?
Certainly. Understanding the product's behavior and how it's used, we can recommend the best fit.
What do you need from us to quote a project?
Product type, target package format, approximate pack size, current or expected volume, and timeline. If you have a spec sheet or ingredient list, even better.
How fast can a packaging project start?
Timeline depends on film, formulation, testing, and volumes. Most projects begin with stability checks, packaging engineering, and small-batch pilot runs before full-scale production. We can typically complete a run within two to three weeks of all materials being delivered to our New Jersey facilities.
