Questions to Ask Before Hiring a Copacker

Selecting the right copacker is one of the most important decisions a CPG brand can make—especially if you’re producing single-serve products like stick packs. The right partnership affects everything from product quality to production efficiency and compliance. The wrong one can set you back for years.

At T.H.E.M. (Technical Help in Engineering and Marketing), we’ve helped hundreds of brands bring their stick pack and single-serve ideas to market. We introduced the stick pack to North America back in the 1990s, and since then we’ve been refining, testing, and scaling this format for products across food, beverage, and nutraceutical categories. We’ve seen firsthand what separates a smooth copacking partnership from a painful one—and it usually comes down to asking the right questions up front.

Table of Contents

1. Do You Have Experience With Products Like Mine?

Stick packs aren’t just small packages—they’re a specialized format that demands experience. Different ingredients behave differently during filling, and the tiniest formulation changes can affect how a product seals, settles, or flows.

We’ve worked with powders, liquids, gels, and nutritional blends of all kinds. That experience helps us anticipate potential issues long before production starts, saving brands from costly trial-and-error. When evaluating a copacker, make sure they’ve produced products similar to yours—and can show you what they’ve learned along the way.

What to ask:

What similar products are you currently producing?
Can you provide client references or case studies?
How do you handle challenging formulations?

2. What Equipment Do You Use?

The quality of a stick pack line depends entirely on the equipment behind it. High-performance form, fill, and seal machines deliver consistent dosing and strong seals that keep products fresh and shelf-stable.

At T.H.E.M., we run multiple Sanko stick pack systems, which are known for precision, speed, and reliability. Each line is configured to match the specific flow characteristics of your product—powder, liquid, or paste—so we can minimize downtime and maximize throughput.

What to ask:

How many stick pack lines do you operate, and what formats can they handle?
Can you accommodate different sizes or SKUs?
What’s your typical defect rate or yield efficiency?

3. How Do You Manage Quality Control?

Consistency isn’t optional—it’s what builds consumer trust. That’s why our facilities are FDA-registered, cGMP-compliant, and ISO-certified, with strict traceability built into every batch.

Before full-scale production, we often start with pilot-scale testing to validate how a product performs during filling and sealing. This process helps identify and correct any issues early, ensuring each production run meets your exact specifications.

What to ask:

How do you ensure lot traceability and product integrity?
What certifications do you maintain?
Can you walk me through your testing and quality verification process?

4. Can You Handle My Growth?

The best copacking partnerships are built for scale. Maybe you’re starting with a single SKU today, but what happens when demand doubles—or triples? You need a partner that can grow with you.

We focus on speed to market and scalable production. Because we handle everything from development to commercialization, we can quickly adjust batch sizes, materials, and schedules to keep up with your growth curve.

What to ask:

What’s your typical lead time for a production run?
How do you handle demand spikes or urgent orders?
What’s your maximum capacity for my product type?

5. What Are Your Minimums?

Not every brand is ready for massive production volumes, and that’s okay. We work with companies at every stage—from pilot runs and R&D samples to high-volume retail production.

Our flexible minimum order quantities allow you to launch small, learn fast, and scale smart without overcommitting to inventory or storage.

What to ask:

Can minimums be adjusted for pilot runs or new launches?
Are MOQs different for powders vs. liquids?
Can we scale up after initial test runs?

6. Who Manages Packaging Materials?

Packaging materials play a big role in cost, quality, and sustainability. Some brands prefer to source their own materials, while others rely on us to manage procurement. We do both.

Our team regularly works with a range of flexible packaging films and laminates, including recyclable and high-barrier options that extend shelf life and meet retailer requirements. Because our equipment is optimized for these materials, we can make sure your packaging looks great and performs even better.

What to ask:

Do you stock standard films, or are they custom ordered?
How do you ensure material quality and compatibility?
Can you work with sustainable or recyclable materials?

7. How Do You Communicate?

The best results come from collaboration. We believe in open, transparent communication from the first conversation to the final shipment. You’ll have a dedicated account manager and production team that keeps you updated every step of the way—no guessing, no surprises.

Our clients often tell us they value being able to “just talk to a real person.” We make that easy. Whether you need to brainstorm, troubleshoot, or pivot mid-project, we’re available and responsive.

What to ask:

Will I have a dedicated point of contact?
How frequently will I receive production updates?
How do you handle unexpected changes or issues?

8. Do You Offer Support Beyond Manufacturing?

For us, copacking isn’t just about filling and sealing—it’s about helping brands get from concept to consumer. That’s why we offer support that extends beyond manufacturing, including R&D, prototyping, regulatory guidance, and logistics coordination.

We partner with clients early in the development process to refine formulations, optimize packaging, and streamline market entry. This approach helps brands move faster and with fewer headaches.

What to ask: