In the consumer packaged goods (CPG) industry, efficiency is more than a target — it is a requirement for remaining competitive. Single-serve packaging formats such as stick packs have grown in popularity because they combine consumer convenience with operational benefits. However, the real cost and speed advantages are only realized when these formats are produced using highly automated systems.

THEM has been at the forefront of this shift. As the first company to introduce stick pack automation to North America and the exclusive North American source for Sanko stick pack machinery, THEM has shaped how brands approach single-serve packaging at scale.

Why Automation Matters in Single-Serve Packaging

Automation directly affects production output, unit cost, and product quality. For single-serve packaging formats, the benefits include:

  • Higher Throughput – Automated stick pack machines can produce thousands of units per hour with consistent quality.
  • Precision Filling – Advanced dosing systems ensure every unit meets exact weight specifications, minimizing product giveaway and reducing waste.
  • Consistency in Sealing and Appearance – Automated sealing ensures barrier integrity and a uniform finished product.
  • Reduced Labor Costs – Fewer operators are required to run and maintain automated lines compared to manual or semi-automated systems.

In a competitive CPG market where margins are tight, these factors have a direct impact on profitability.

THEM’s Early Adoption and Market Leadership

THEM introduced stick pack technology to the North American market in 1996. At that time, stick packs were already popular in Asia and Europe, but largely unknown in the United States. By investing in high-speed automated machinery and building the expertise to run it efficiently, THEM enabled domestic brands to take advantage of the format without sending production overseas.

Today, THEM continues to lead the industry by combining high-capacity automated production with in-house research and development capabilities. This allows clients to bring new products to market faster while maintaining strict quality and compliance standards.

The Sanko Advantage

THEM’s automation capabilities are built on Sanko machinery — widely regarded as the gold standard in stick pack technology. Sanko Machinery Co., based in Japan, invented the stick pack format and remains the global leader in form/fill/seal technology for single-serve applications.

Key Features of Sanko Stick Pack Machines:

  • High-Speed Performance – Models such as the FC1000 α series can produce at high volumes with minimal downtime.
  • Format Versatility – Sanko machines can run powders, granules, liquids, and pastes, making them suitable for a wide range of CPG products.
  • Advanced Filling Technology – Auger-fill options for powders and granules, liquid-fill options for beverages and viscous products, and piston-fill systems for pastes.
  • Precision Control – Human-machine interface (HMI) systems allow precise adjustments to filling speed, sealing temperature, and other parameters for consistent output.
  • Proven Reliability – Designed for continuous operation, reducing unplanned downtime and maintenance costs.

By operating as the exclusive North American source for Sanko equipment, THEM ensures clients benefit from both world-class machinery and the operational expertise to get the most out of it.

Operational Impact for CPG Brands

Automated stick pack production impacts multiple areas of the supply chain:

  1. Production Efficiency – Automation allows large production runs without proportional increases in labor, keeping per-unit costs stable even as volumes grow.
  2. Quality Control – Integrated vision and weight-check systems detect and reject defective units before they reach packaging or shipping.
  3. Faster Changeovers – Sanko machines are designed for quick format changes, allowing brands to switch SKUs or adjust package sizes without lengthy downtime.
  4. Scalability – A well-configured automated line can scale output quickly to meet seasonal demand or respond to market opportunities.
  5. Regulatory Compliance – Automation helps ensure consistent lot coding, labeling, and packaging integrity to meet FDA and international standards.

Reducing Time-to-Market

For new product launches, speed is a competitive advantage. THEM’s combination of automation, Sanko machinery, and in-house R&D shortens the path from concept to full-scale production. By running small-batch trials on the same equipment used for commercial production, issues can be identified and resolved before large runs, eliminating delays and costly rework.

Partnering with an Expert

Automation delivers its best results when paired with operational expertise. THEM’s decades of experience with Sanko stick pack machinery, combined with their role as the first to bring the technology to North America, make them a unique resource for CPG brands. From packaging design to material selection to full-scale automated production, THEM provides the complete infrastructure for efficient, high-quality single-serve packaging.

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