LIQUID PACKAGING
Liquid packaging is where most co-packers hit their limits.
Viscous products leak. Particulates end up in seals. Headspace shortens shelf life and complicates production. These are not edge cases. They are the reasons liquid brands switch co-packers.
T.H.E.M.'s liquid filling equipment is built to solve exactly these problems. Sanko sealing technology clears inclusions and particulates that would cause leakers anywhere else. Our sachets run zero headspace as standard, extending shelf life and giving your brand more flexibility with retailers and distributors. From water-thin to heavy paste, we fill it accurately, seal it cleanly, and do it at volume.
Our Liquid Lines
Liquid Sachet Packaging
Sachets are a workhorse format. Ours are flexible in size, adaptable across viscosities, and built for brands that need precision at scale. We fill sachets from 1mL and up, across viscosities ranging from liquid to heavy pastes. Bag width is customizable from 40–160mm. Custom die-cut options are available for brands wanting a differentiated format their customers will recognize on sight. Clean seals and leak-free performance are non-negotiable: our Sanko equipment and in-house quality team make sure of it.
Liquid Stick Packaging
The stick pack is one of the most recognizable single-serve formats in the market, and one of the most powerful branding surfaces available at that size. Slim, portable, and printable along the full length, liquid sticks are the format of choice for premium beverages, supplements, and functional ingredients where the package needs to work as hard as the product inside. Our Sanko equipment literally invented the format. Our liquid stick line delivers fill accuracy, seal integrity, and throughput, consistently at volume. If your brand is entering or scaling in this space, Sanko machinery ensures you're doing it right.
Thermoform Fill Seal Cups
Thermoformed cups are the go-to for sauces, dips, condiments, and semi-liquids that need a rigid, portion-controlled format. Ideal for applications up to two ounces, they're well-suited for foodservice, retail meal kits, and any application where a flexible pouch isn't the right fit. Clean presentation, reliable seals, and a format consumers know how to use.
Why Brands Choose T.H.E.M. for Liquid Single-serve Contract Packaging
- Zero headspace sachets — extends shelf life and gives your brand more room to negotiate distribution and retail placement
- Ultrasonic seal bar — agitates the sealing area before closing, clearing particulates and inclusions that cause leaks at other co-packers
- Wide viscosity range — water-thin to heavy pastes including honey, nut butters, and syrups, filled accurately and repeatably
- Zero recalls in our history — the result of disciplined quality systems, in-house testing, and a quality team embedded on the floor
- Dedicated allergen facility — separate facility for nuts and other allergens for brands with strict cross-contamination controls
- Sanko OEM partnership — we introduced Sanko machinery to North America in 1996 and run it in our own facilities. Nobody in the country knows this equipment better.
Your liquid product. Our lines. Ready to figure out the details together?
Liquid Packaging FAQs & Resources
What is the best packaging for single-serve liquids?
Stick packs and sachets are two of the most efficient formats for single-serve liquid packaging. They offer lightweight materials, controlled dispensing, and strong seal integrity, making them ideal for beverages, sauces, oils, gels, supplements, and personal care products.
How do you prevent leaks in liquid sachets and stick packs?
Leak prevention comes from a combination of optimized film structures, proper heat-sealing parameters, and precision filling. At T.H.E.M., we engineer each run to match the viscosity and product behavior of your liquid, ensuring consistent seals and robust performance through the supply chain.
What viscosities can you package?
We can fill everything from thin, water-like liquids to heavy pastes. Our equipment handles viscosities ranging from <1 cP to >100,000 cP — including honey, nut butters, syrups, oils, lotions, and more.
Do you offer eco-friendly liquid packaging options?
Yes. We can work with a variety of films. If you haven't found a film for your project, we can help provide materials with reduced environmental impact, recyclable film structures where applicable, and packaging designs that minimize waste and shipping weight.
Which industries use liquid stick packs and sachets?
Food & beverage, nutraceuticals, sports nutrition, personal care, beauty, household cleaning, quick-serve foodservice, and travel retail all rely on single-serve packaging for dosing accuracy, convenience, and cost efficiency.
Do you support custom shapes or die-cut formats?
Absolutely. Our innovative machinery allows brands to create unique custom die-cut shapes that improve usability, differentiate on shelf, and align with brand identity.
How fast can a liquid 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 facility.
Trust the Leading Single-serve Manufacturer in North America
When you partner with THEM, you’re not just choosing any liquid packaging solutions provider; you’re opting for the leading name in North America. We take pride in our dedication to quality, our commitment to eco-friendly practices, and our passion for using raw materials that leave minimal environmental footprints. From plastic packaging to more sustainable alternatives, we’re here to make sure your packaging liquids strategy is top-tier. So, if you’re searching for the perfect packaging for liquid, you’re in the right place!
Benefits of Liquid Packaging
The right package elevates the entire moment-of-use experience for consumers. This is especially true in single-serve formats, where quality, precision, and convenience determine whether a product delights or disappoints. Our stick and sachet options are precision-engineered around that reality. Here’s how they benefit your business and customers:
Flexible Packaging
Adapting to any size, shape, or type of liquid, our flexible packaging solutions are a game-changer. Whether you have a thick syrup or a thin beverage, our packaging materials mold seamlessly, ensuring that your product stands out on the shelves. Additionally, flexible packaging is typically lighter than its rigid counterparts, leading to potential savings in shipping and transportation costs.
Eco-Friendly
We’re living in an age where consumers are becoming increasingly conscious about their environmental footprint. With our eco-friendly packaging for liquids, brands can confidently communicate their commitment to sustainability. By incorporating recycled materials and designing with a focus on reducing environmental impact, our packaging not only ensures safety for your liquids but also promotes a greener planet.
Enhanced Supply Chain Efficiency
Effective packaging goes beyond aesthetics and function. With our top-grade packaging, your supply chain processes will benefit too. How? Well-packaged products mean reduced spillage, fewer returns due to damage, and more efficient stacking and storage. The outcome? A smoother, more cost-effective journey from your factory to the hands of your customers.
When you choose our liquid packaging solutions, you’re not only ensuring top-tier containment for your products, but you’re also adopting a strategy that resonates with modern consumers, optimizes costs, and promotes a healthier environment.
