A customized pharmaceutical gel stick pack packaging machine project for Aurora in Australia, designed to increase sports gel packaging capacity to 400 packs per minute while reducing product trapping, leakage, bag bursting, dripping, and labor dependency.
Aurora
Sports gel / sports nutrition manufacturing
Australia
Sports gel
Viscous gel, sticky texture, liquid or semi-liquid product, requires accurate filling, anti-drip control, clean sealing, and stable long stick pack forming
High-speed pharmaceutical gel stick pack packaging automation project
Irregular long stick pack
May 2026
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Aurora, a sports gel manufacturer in Australia, needed to increase packaging capacity after receiving new orders. The customer had been using two small vertical liquid packaging machines, but the output was too low to meet the new production demand. In addition, the existing machines had recurring problems such as product trapping, leakage, dripping, bag bursting, and high labor costs.
To solve these challenges, eixpack provided a customized pharmaceutical gel stick pack packaging machine solution for sports gel products. The system was designed with automatic feeding, servo ceramic pump filling, stick pack forming and sealing, laser coding, cutting, and finished pack output. The project target was to reach up to 400 packs per minute while improving filling stability, sealing quality, and overall production efficiency.
Aurora was using two small vertical liquid packaging machines, but their combined output could not meet the demand created by new orders. Low packaging capacity directly affected production scheduling, delivery planning, and the ability to handle larger customer orders.
Sports gel is viscous and sticky. When the gel is not filled cleanly or remains near the sealing area, it can cause product trapping during sealing. This leads to unstable sealing quality, poor package appearance, and a higher reject rate.
The customer’s existing machines had leakage and dripping problems. For sports gel packaging, leakage not only wastes product but also increases cleaning work and may affect hygiene, shelf appearance, and customer satisfaction.
Unstable filling volume, poor sealing, or trapped product in the seal area can increase the risk of bag bursting. Bag bursting causes material waste, production interruption, and additional labor for cleaning and sorting.
Because the existing machines required frequent monitoring and manual handling, Aurora needed more labor to maintain production. As order volume increased, labor cost became a major pressure on the customer’s packaging operation.
Aurora wanted to upgrade from two low-output vertical liquid packaging machines to a high-speed pharmaceutical gel stick pack packaging system that could support larger sports gel orders.
The main goals of the project included:
eixpack provided Aurora with a customized pharmaceutical gel stick pack packaging machine designed for high-speed sports gel packaging. The system was configured for viscous gel filling, irregular long stick pack forming, stable sealing, laser coding, and continuous high-speed production.
Unlike the customer’s previous small vertical liquid packaging machines, this solution was built as an integrated automated stick pack packaging line. It combines automatic feeding, servo ceramic pump filling, stick pack forming, sealing, laser coding, cutting, and finished pack output into one complete system.
The automatic feeding system transfers sports gel into the filling system continuously and reduces manual feeding work. For high-speed production, stable feeding is important because it helps keep the packaging machine running smoothly and reduces production interruptions.
For Aurora, this module helps reduce labor dependency and provides a more stable material supply for the target output of up to 400 packs per minute.
The servo ceramic pump filling system is used for accurate and stable sports gel dosing. It is suitable for viscous and semi-liquid products that require controlled filling. Compared with ordinary liquid filling systems, the servo ceramic pump helps improve filling consistency, reduce dripping, and control product residue around the sealing area.
For Aurora’s sports gel product, this filling system was a key part of the solution because the previous machines had problems with product trapping, leakage, and unstable filling. More controlled filling helps reduce overfilling, product waste, and contamination near the seal.
The stick pack forming and sealing system forms the packaging film into irregular long stick packs, fills the sports gel, and seals the package. The sealing section is designed to improve sealing stability and reduce the risk of gel being trapped in the seal area.
This helps Aurora reduce leakage, bag bursting, and rejected packs while improving the appearance and consistency of the final sports gel packages.
The laser coding system can print production information such as date, batch number, or traceability codes on the stick packs. Compared with traditional coding methods, laser coding provides clean, permanent, and consumable-free marking, which is suitable for high-speed packaging lines.
For Aurora, laser coding helps improve packaging traceability and reduces the need for consumables such as ink or ribbon.
With this integrated pharmaceutical gel stick pack packaging machine, Aurora can replace the limitations of its previous two small vertical liquid packaging machines. The new system is designed to support a target output of up to 400 packs per minute, reduce product trapping, improve sealing stability, lower leakage risk, reduce bag bursting, and lower labor dependency.
This solution is suitable for sports gel because it combines automatic feeding, servo ceramic pump filling, clean sealing, laser coding, and high-speed stick pack production in one complete system.
For this project, eixpack supported Aurora with a complete service process from requirement analysis to machine delivery and after-sales support.
eixpack reviewed Aurora’s production challenges, including low output, leakage, product trapping, bag bursting, dripping, and high labor cost. The project target of 400 packs per minute was used as the main reference for solution planning.
Because sports gel is viscous and sticky, the packaging solution needed to consider filling stability, anti-drip control, sealing cleanliness, and packaging material compatibility.
The machine was selected according to the customer’s product type, target output, bag format, and packaging quality requirements. The goal was to provide a high-speed stick pack solution suitable for sports gel packaging.
eixpack can support equipment layout planning to help the customer connect the stick pack packaging machine with its production process and downstream packing operation.
Commissioning can focus on filling stability, sealing quality, coding position, cutting performance, and finished pack output. For this type of project, particular attention is given to reducing leakage, dripping, product trapping, and unstable sealing.
Operator training can include machine operation, parameter adjustment, daily cleaning, troubleshooting, and basic maintenance guidance.
“The new stick pack packaging solution helped us address the main issues we had with our previous machines, including low output, leakage, product trapping, and unstable sealing. The servo ceramic pump filling system is suitable for our sports gel product, and the higher speed gives us more confidence in handling new orders. eixpack also provided professional support during the project, helping us improve both production efficiency and packaging quality.”
— Production Manager, Aurora
This solution works because it is designed around the real packaging challenges of sports gel products. Sports gel is different from ordinary liquid products. It is more viscous, sticky, and more likely to remain near the filling nozzle or sealing area. If the machine is not properly configured for gel packaging, it can cause dripping, poor sealing, leakage, or bag bursting.
The pharmaceutical gel stick pack packaging machine is suitable for Aurora because it combines automatic feeding, servo ceramic pump filling, stable stick pack forming, clean sealing, laser coding, and finished pack output in one system. This helps the customer improve speed while also controlling the quality issues that affected the previous packaging process.
For brand manufacturers and contract manufacturers, this type of solution is valuable because it supports high-volume production, consistent packaging quality, and future capacity expansion.
eixpack can support similar sports gel and viscous liquid packaging projects with complete project service capabilities.
Our service capabilities include:
Pharmaceutical gel stick pack packaging machines can be used for sports gel, energy gel, nutrition gel, pharmaceutical gel, liquid supplements, semi-liquid products, and other viscous products that require small-dose stick pack packaging.
Yes. The machine can be customized for sports gel products, especially when the product is viscous, sticky, and requires clean filling, stable sealing, and portion-controlled packaging.
A servo ceramic pump helps provide accurate and stable filling for viscous gel products. It can improve filling consistency, reduce dripping, and help control product residue near the sealing area.
For Aurora’s project, the solution was designed with a target output of up to 400 packs per minute. Actual speed depends on product viscosity, bag size, packaging material, filling volume, and final machine configuration.
Yes. The system can be configured with controlled gel filling, stable sealing, and anti-drip design to help reduce leakage, dripping, and product residue around the sealing area.
Yes. The machine can be equipped with a laser coding system to print production date, batch number, or traceability information on the stick packs. Laser coding is suitable for high-speed packaging lines because it is clean, permanent, and consumable-free.
Yes. The packaging system can be customized according to the required bag shape, including irregular long stick packs for sports gel and similar products.
To prepare a suitable solution, eixpack usually needs product samples, filling volume, bag size, packaging material, target speed, bag shape, production layout, and any special sealing, coding, or cutting requirements.
Whether you package sports gel, energy gel, pharmaceutical gel, or other viscous liquid products, eixpack can help you design a customized stick pack packaging solution based on your product, bag format, output target, and factory requirements.
Skip the back-and-forth. Send us your material specs and speed requirements for a custom machine layout.
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