Flexible packaging, or flex pack, is one of the fastest-growing packaging formats on the market. Pouches are lightweight, durable, cost-effective, and highly customizable, but selecting the right material structure is critical. The proper combination of films and barriers will protect your product, support your brand story, and align with your sustainability goals.

Pouches are also an efficient and budget-friendly option because the digital printing method means we can easily set up multiple SKUs to run in the same batch. Manufacturers are introducing more sustainable and recyclable options.

If MET PET, EVOH, All-PE and PCR sound like so much alphabet soup, let us help you choose the best option for your brand and product.

Our most popular material

The most common material our customers use is 3mil MET PET (metalized polyester). The MET PET protects against moisture, oxygen, and light, so it is great for food products, pet treats, nutraceuticals, coffee, and other oxygen-sensitive items.

The metalized layer helps extend shelf life while maintaining product freshness and flavor. MET PET is strong and puncture-resistant, which is especially important for products with sharp edges or heavier fill weight. They also provide a sleek, metallic interior that can increase perceived quality.

This option—which comes in 2mil, 4mil, and other thicknesses too—is usually the top choice when maximum protection and extended shelf life are the top priorities. It comes in reflective metallic, clear, or white, depending on your design goals.

Another barrier option

EVOH (ethylene vinyl alcohol) is a transparent barrier option that can be better against certain types of oils, but not as trustworthy for humidity. It is an excellent oxygen, gas, and odor barrier.

Sustainable options

• All-PE (polyethylene) pouches are a mono-material rather than a layered blend, so they are recyclable in areas where PE film recycling is available.
• PCR (post-consumer recycled) material lowers environmental impact by incorporating plastics recyclers have already diverted from landfills. It can be combined with different barrier layers.
• Industrially compostable films (usually bio-based) can be a fit for short shelf-life products creating zero waste. There is not currently a food-safe compostable barrier material on the market, but several potential options are in research and development.

Choosing the right material

The perfect material for your flexible packaging depends on

• The product’s sensitivity to oxygen, moisture, and light
• The product’s desired shelf life
• Sustainability goals
• Brand goals
• Budget

And of course we have many other materials and combinations available; these are merely the most popular. The material can make or break the success of your packaging so whether you are just getting started or have a fully detailed structure you want to match, contact us today to get in touch with one of our flex pack experts. We love to help brands grow!