A customized dual-lane electrolyte powder stick pack machine project designed for dusty, oily powder filling, aluminum film stick packs, higher output, improved dosing consistency, and reduced material waste.
Liquidsun Ltd
Functional beverage manufacturer
United Kingdom
Electrolyte powder
Powder; dusty; oily; easy to cause product trapping during filling and sealing
Customized powder stick pack packaging project
Round-corner stick pack with easy-tear notch
Mid-July 2025
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Liquidsun Ltd, a functional beverage manufacturer in the United Kingdom, required a customized packaging solution for electrolyte powder stick packs.
The product was powder-based, dusty, and oily, which created two major production problems: product trapping during sealing and packaging material waste.
The customer wanted to improve output, enhance filling consistency, and support multiple packaging specifications for future product expansion.
To meet these requirements, EIXPACK provided a customized dual-lane Electrolyte Powder Stick Pack Machine with automatic feeding, anti-static support, dust extraction, and a finished pack conveyor.
The project was designed around aluminum film stick packs and the real behavior of electrolyte powder during feeding, dosing, forming, sealing, and finished pack handling.
For similar applications, EIXPACK also provides a dedicated Electrolyte Powder Stick Pack Machine solution for hydration powder, mineral blends, sports nutrition powder, and functional beverage powder.
Dusty and oily electrolyte powder can easily remain near the sealing area. When powder is trapped in the seal, it may affect sealing quality, finished pack appearance, and production stability.
When film sealing is affected by powder contamination or unstable film handling, the line may produce more rejected packs. This increases aluminum film consumption and raises the long-term packaging cost.
Dusty and oily powders may not flow as predictably as free-flowing powders. Without suitable feeding and dosing control, fill weight variation can increase and affect product consistency.
For a functional beverage manufacturer, manual or low-output packaging can become a bottleneck when product demand increases. Liquidsun Ltd needed a solution that could increase output while keeping the line manageable.
Electrolyte powder brands often develop different serving sizes, formulas, flavors, and market versions. The packaging system needed to support future specification changes instead of being limited to one fixed pack format.
The main goal of this project was to help Liquidsun Ltd build a more stable and scalable electrolyte powder stick pack production system. The project focused on:
EIXPACK supplied a customized dual-lane Electrolyte Powder Stick Pack Machine for Liquidsun Ltd. The solution was designed for aluminum film stick packs and dusty, oily electrolyte powder.
Instead of treating the machine as a standard powder packer, the configuration focused on three key production risks: powder floating, product trapping, and packaging film waste.
The machine system included the following major functional modules:
The dual-lane structure allows two stick packs to be formed and filled at the same time. This helps improve output compared with single-lane packaging while keeping the system suitable for controlled production and future specification changes.
The automatic feeding system helps deliver electrolyte powder to the dosing area more consistently. This reduces manual powder loading, supports longer continuous operation, and helps maintain a more stable powder supply for filling.
For electrolyte powder, the dosing section must be selected according to powder density, oiliness, dust level, flowability, and target filling weight. The system can be configured with an auger-type filling structure suitable for powder stick pack applications to support controlled filling and reduce fill weight variation.
Because fine powder can be affected by static electricity, the anti-static device helps reduce powder adhesion around the film and filling area. This supports cleaner film movement and helps reduce the chance of powder being carried into the sealing position.
The dust extraction unit helps remove airborne powder around the filling and sealing area. For dusty electrolyte powder, this is important because cleaner sealing conditions can help reduce product trapping, improve sealing appearance, and reduce rejected packs.
The forming and sealing section shapes the aluminum film into stick packs and seals each pack. For oily and dusty powder, stable film tracking, proper sealing pressure, and cleaner sealing surfaces are important to reduce film waste and improve finished pack consistency.
The machine can complete stick pack cutting and transfer finished packs to the output section. A stable output process helps operators collect products more efficiently and reduces unnecessary handling after packaging.
The finished pack conveyor transfers packed electrolyte powder sticks away from the machine in an orderly manner. This supports smoother post-packaging handling and can prepare the line for future counting, cartoning, or secondary packaging upgrades.
This solution works because electrolyte powder packaging is not only a speed issue.
For dusty and oily powders, the main risks usually appear around feeding stability, powder control, sealing cleanliness, and film waste.
A standard powder packaging machine may increase speed, but if powder trapping is not controlled, higher speed can create more rejected packs.
The dual-lane EIXPACK solution balances output and control. Automatic feeding supports stable material supply.
Anti-static support helps reduce powder adhesion. Dust extraction helps keep the filling and sealing area cleaner.
The forming, sealing, cutting, and conveyor sections work together to create a more controlled stick pack packaging process.
For functional beverage manufacturers, this type of solution is suitable because it supports single-serve powder packaging, aluminum film protection, future flavor or specification changes, and cleaner production management.
For this type of electrolyte powder stick pack project, EIXPACK can support the customer from early requirement analysis to long-term production optimization. The service scope can include:
“EIXPACK understood the main issue we had with electrolyte powder packaging: product trapping and film waste. The dual-lane stick pack machine configuration, especially the automatic feeding, anti-static support, and dust extraction system, matched our production needs. The solution gives us a more stable way to improve output, reduce unnecessary waste, and prepare for multiple product specifications.”
— Representative Customer Feedback, Liquidsun Ltd
EIXPACK can support similar powder stick pack projects with application-specific engineering and packaging automation experience. For contract manufacturers, brand manufacturers, sports nutrition brands, and powder product manufacturers, EIXPACK can provide:
This machine is designed for electrolyte powder and can also be configured for similar functional beverage powders, hydration powder, mineral blends, sports nutrition powder, vitamin powder blends, and other powder stick pack products.
Yes. For dusty and oily powders, the system can be configured with automatic feeding, anti-static support, and dust extraction to help reduce powder floating, powder adhesion, and seal contamination.
Yes. The system can be customized according to filling weight, stick pack width, stick pack length, film roll width, sealing requirement, and target output. Final size compatibility should be confirmed before quotation.
Electrolyte powder usually requires a powder dosing system selected according to density, flowability, dust level, oiliness, and target filling weight. Auger filling is commonly considered for controlled powder stick pack filling.
Yes. This project was designed for aluminum film stick packs. Final film compatibility depends on film structure, thickness, sealing layer, print mark position, and sealing temperature range.
Please provide product type, powder characteristics, filling weight, stick pack size, film material, target speed, required lane number, packaging sample, and whether future counting or cartoning connection is needed.
EIXPACK can provide requirement analysis, sample evaluation, machine configuration support, installation and commissioning guidance, operator training, maintenance guidance, spare parts support, and remote or on-site technical support depending on project needs.
A dual-lane stick pack machine is suitable for customers who need higher output than single-lane or manual-assisted packaging, while still keeping investment, layout, and operation manageable. For larger output, additional lanes or downstream automation can be considered.
If you are packaging electrolyte powder, hydration powder, sports nutrition powder, or functional beverage powder, EIXPACK can help evaluate your powder characteristics, film material, stick pack size, and production target to recommend a suitable packaging solution.
Skip the back-and-forth. Send us your material specs and speed requirements for a custom machine layout.
EIXPACK engineers packaging machinery and automated packaging lines for nutraceutical, supplement, pharmaceutical, food, and contract manufacturing applications.
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