The hunt for the perfect barrier packaging for your product can take you in many different directions. There are several factors to consider when making your choice, including aesthetics and barrier protection levels.

In this article, we will explore what barrier packaging is, how it works, the different types, and what would work best for you.

WHAT IS BARRIER PACKAGING?

Barrier packaging – also known as modified atmosphere packaging (MAP) – is made from materials that provide a barrier between the product inside and the environment outside.

The movement of gases into or out of a package can lead to changes in the product and a reduction in its shelf life. Barrier packaging is a method for preserving food without the use of chemicals. The right material depends on the product being wrapped and the desired storage. Consumable products can vary drastically in their requirements for packaging and storage, based on Federal and state guidelines, as well as company preferences.

Barrier packaging can increase natural shelf life by 2-10 times. Cooked pasta, for example, can be stored for up to 21 days in an atmosphere of 50% carbon dioxide and 50% nitrogen.

The packaging’s effectiveness is determined by two different measurements: moisture vapor transmission rate and oxygen transmission rate.

The Moisture Vapor Transmission Rate is expressed in grams per 100 square inches over 24 hours (g/100 in²/24 hr), measuring the amount of moisture passing through 100 square inches of material in 24 hours.

The Oxygen Transmission Rate is expressed as CC/100 in²/day, measuring square inches per 24 hours.

TYPES OF BARRIER PACKAGING

Barrier packaging comes in many forms, but perhaps the first one was the tin can. Its use started in the early 1800s and has the advantage of being inexpensive, rigid, thermally stable, easy to process on high-speed manufacturing lines, and recyclable. It’s still in wide use today.

The other widely used material is plastic, whether it is used in flexible pouches or rigid containers for milk.

Glass and aluminum foil also act as barrier packaging, but each one has drawbacks. Glass is easily breakable, and foil, in thinner gauges, can suffer from “pinholing” (tiny holes). Foil is also not durable enough to repeated flexing and can develop more pinholes during machining and shipping. Explore our article on barrier packaging materials to discover which materials are best suited for your specific application.

LEVELS OF BARRIER PACKAGING

Each type of barrier packaging has different levels of protection.

While only glass and metal provide absolute barriers to gases and volatiles, plastic barriers are typically categorized into four types: basic single-layer, coextruded, coextruded with additives, and high-performance. The barrier properties are proportional to film thickness and become more costly with each level.

Basic Single: These are the simple, one-layer bags, such as poly bags. The bags are cheaper, but polyethylene bags lack the barrier properties necessary for modified atmosphere packaging. Once air is removed to form a vacuum within the bag, external air will slowly seep back into the bag.

Coextruded: Combines two single-layer barriers to produce more robust laminated packaging that offers greater moisture resistance. Our 3 Mil and 4 mil vacuum bags are considered standard strength, capable of handling most vacuum packaging applications. These bags are strong poly nylon woven bags designed to increase shelf life and protect products.

Coextruded With Additive: Materials at this level are plastics coextruded with EVOH (ethylene-vinyl alcohol copolymer), a highly effective oxygen barrier. Packaging using this method is a custom product and cannot be ordered online. Request a quote from us, and we will send a formal estimate for bags with an EVOH additive.

High-Performance: These barrier materials are made by laminating materials that include foils with the higher barrier materials such as PET (polyethylene terephthalate). Our reclosable metalized barrier bags feature stronger barrier properties than co-extruded poly/nylon bags. The fully opaque material conceals products not only from oxygen but also from light.

CHOOSING BARRIER BAGS

To select the appropriate barrier packaging, consider the product’s shelf life, storage conditions and requirements, the desired finished appearance, and whether exposure to light should be minimized or eliminated.

Cost should also be evaluated. While it is true that higher barrier packaging is the most effective, it is also the most expensive. Ensure you are getting the product you need at an affordable price. Ordering in bulk is an effective way to lower costs if you are certain the product will work for your application.

The market is full of products that look similar but have different barrier properties. It is always a good idea to consult a packaging expert if you have any questions about barrier packaging.

U.S. Packaging & Wrapping offers a range of high-quality barrier packaging solutions. For your packaging needs, visit our website at uspackagingandwrapping.com or contact us by phone at 1-800-441-5090 or by email at [email protected].