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Flexible Packaging Materials Buying Guide

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Elva

Jul. 14, 2025
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Flexible Packaging Materials Buying Guide

From consumer goods to electronics. From cosmetics to medical supplies. Flexible packaging is a crucial material in the supply chain of many industries and products.

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Flexible packaging combines the best qualities of plastics and films. These versatile packaging supplies are a functional solution that requires minimal production costs.

Flexible packaging is any package or any part of a package whose shape can be readily changed.” Common examples of flexible packaging include bags, pouches, shrink films, tubes, sleeves, and carded packaging.

In this article, we detail why flexible packaging is so beneficial. And, we also outline considerations for purchasing flexible packaging for your products.

Why Use Flexible Packaging?

Flexible packaging is a solution that businesses turn to for a variety of reasons. For starters, it’s less expensive than rigid packaging. But, it also offers excellent durability and product protection. Polyolefin shrink films are a popular high-quality material. These films are approved by the FDA to increase shelf life.

The quality of flexible packaging isn’t its only calling card, however. It’s also touted for its ability to be tailored to fit the specifics of any product. It’s possible to package products of many shapes and sizes with flexible packaging. And, you can do this with an array of materials.

That is good news for businesses creating packages that help sell their products. With flexible packaging, companies can think outside of the box to engage consumers.

Speaking of consumers, flexible packaging helps designers create attractive packages. These packages are more convenient for consumers. Additionally, flexible packaging is a form of sustainable packaging. These alternatives include cardboard, glass, and other types of rigid packaging.

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Flexible Packaging Material Options

There are many different options for flexible packaging materials. For the sake of brevity, we’ll limit our list to the most popular items.

Keep in mind that working with a packaging partner will help you select the best packaging. When you use the ideal solutions, you’ll save time and money in the long run.


Stand Up Pouches

One of the best alternatives to traditional packaging is stand-up pouches. They function as their name suggests – standing upright on shelves. This packaging has an airtight closure.

Stand-up pouches (also known as flexible pouches) are extremely easy to pack, and they have incredible branding capabilities through digital printing. Stand-up pouches can be custom printed with eye-catching graphics and breathtaking colors.

Stand-up pouches are fully customizable to your needs. And stand-up pouches have multiple barrier layers of protection. They can suit nearly any product, many of which are listed in the flexible films section below.

Flexible Films

As you can already tell, there are many different flexible film materials. Here are 14 of the most popular:

  • (EAA) Ethylene Acrylic Acid – A tie layer between aluminum foil and other polymers.
  • (EVA) Ethylene Vinyl Acetate – An adhesive layer, moisture barrier, and heat-sealable food contact layer.
  • (EVOH) Ethylene Vinyl Alcohol – An oxygen barrier typically placed between PE/PP films, EVOH must be protected from moisture.
  • (PA) Polyamide – A film that works well as an outer layer, PA provides machinability, a gas/aroma barrier, heat resistance, and will not stick to a sealer bar.
  • (PC) Polycarbonate – A moisture and heat-resistant barrier with machinability.
  • (PE) Polyethylene – Another heat-sealable food contact layer, as well as a moisture barrier. It can also be combined with gas/aroma barriers such as (EVOH, PA).
  • (PEN) Polyethylene Naphthalate – A gas/aroma barrier with machinability and heat resistance.
  • (PET) Polyethylene Terephthalate – A film that provides machinability strength, PET is all of a gas/aroma barrier, moisture barrier, and heat-resistant.
  • (PET-G) Glycol-Modified Polyethylene Terephthalate – A heat-sealable food contact layer.
  • (POF) Cross-Linked Polyolefin – A heat-sealable film best suited for food packaging but also used to laminate print products. Made using a cross-direction technique in which film is stretched both mechanically and manually.
  • (PP) Polypropylene – A moisture barrier that can be combined with other gas/aroma barriers or coated with heat-seal coatings such as acrylate and PVDC.
  • (PS) Polystyrene – A printable and gas-permeable film that can be combined with other gas/aroma barriers.
  • (PVDC) Polyvinylidene Chloride – An O2 barrier and heat-sealable layer that provides gloss and protects print.
  • (PVC) Polyvinyl Chloride – A gas/aroma barrier with machinability.

Foil Packaging

Foils are used mainly by the food and pharmaceutical industries. Foil packaging keeps food fresh. And, it keeps food safe by blocking contaminants, increasing your products’ shelf life. It is also a recyclable material.

Additional Protective Packaging

Flexible packaging materials range in type and size. They can be designed for all kinds of packaging needs – from small products to large equipment. Flexible packaging can also be used to palletize bulk products.

Air pillows are a great example of lightweight and secure protective packaging. They protect products from shock and vibration. They do this during transit.

Air Pillow Machine

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Air pillows are easy to recycle and dispose of. This is especially true when compared to messy packing peanuts. Electrostatic discharge (ESD) bagging is especially great for packaging sensitive electronics. This is done to avoid damage due to static and friction.

How Do You Know If You’ve Chosen The Ideal Flexible Packaging?

Is your goal to increase your product’s shelf life? Do you want to minimize product loss during transit? You can’t know if you’ve chosen the right solution until you’ve defined all of your requirements. You need some parameters to give you a direction.

In terms of protection, you’ll also need to define what your products need protection from. Do you have a long shipping process with many risks for error?

Will your product be delivered to a location at a high altitude? Does the area have high humidity or low temperatures? These considerations all impact what packaging is the optimal solution.

You’ll also need to set your budget, but don’t make the mistake of being too short-sighted. Beyond cost, you must consider whether you’ll need to set up new packaging machinery (for example, form fill and seal machinery).

And, you may need to add secondary packaging to maintain the safety of your product. As early as possible, communicate with your suppliers, aware of your budget. Discuss any financial constraints. This will help you save time in the material selection process.

Speaking of which, you’ll need to budget time for review and modifications. Don’t expect quick fixes to be cost-effective. Give yourself time to review your flexible packaging.

Top Packaging Considerations for Premium Pet Food Brands

A recent report by Packaged Facts estimates the overall U.S. pet food and treats market at $39 billion in . Given the increase in pet adoption in , seasoned and new pet parents alike are seeking the best options for their four-legged companions.

Brands must analyze every component of their operation and product to provide an option that is going to stand out to consumers. One item that should not be overlooked is packaging. While many brands are implementing cost-saving measures in their packaging and removing convenience features, premium pet food brands can fill the void and meet the demands of eco-conscious consumers who want the best products for their pets and the environment. Offering reclosable flexible packaging can keep brands on the cutting edge of the optimal consumer experience, with extended shelf-life, easy storage, contaminant protection and more. Here’s why.

1. People Are Willing to Spend More for Pets & the Environment

Pets have truly become family members, and this has led to increased expectations for the products we purchase for them, especially food. This includes all-natural ingredients, better health benefits and sustainable options that help protect the world in which our pets live. While these premium options come at a cost, pet owners are willing to pay for them. This is particularly true when it comes to younger owners. Seventy-three percent of millennials and 68% of Gen Zers are willing to spend more for sustainable products, according to First Insight. Brands that put an emphasis on better packaging can stand out from those cutting costs on convenience features.

2. Product Protection is Vital

FINN CADY reports that 80% of dog and cat owners agree that what their pet eats impacts its health. For pet food brands, this means product integrity is a must. Packaging plays a major role in maintaining quality, from manufacturing through consumption.

FDA-recognized manufacturing processes and approved supplier materials are crucial for creating packaging that does not have a negative impact on the food or pet. Packaging that includes low-quality resins, inks and adhesives could be prone to leaching, which can create an undesirable odor or taste. This could prevent the pet from eating the food, or worse, make her sick.

Quality flexible packaging materials and designs provide excellent product protection when paired with compatible closure technologies. The key to pet food freshness is a secure oxygen barrier that protects the food from contaminants like bacteria, pests, odor, light and moisture. Using closures with high-integrity seals that don’t leak, gap or distort ensures that your product will be fresh upon purchase and consumption. Also, flexible packaging’s durable, puncture-resistant materials help the product survive the supply chain, whether through brick-and-mortar or e-commerce.

3. Pet Owners Want Convenient Products

While pet owners want products that are good for their pets, they also want products that are convenient and functional. A package that is difficult to open, seal and pour makes for a frustrating user experience and a potential mess. Additionally, a poor package experience can lead to the pet owner transferring the food to a secondary container, which can cause the product to lose its freshness or become contaminated. This results in lost branding to the secondary container and being linked to an inferior product.

Storing dry pet food in its original package helps maintain the food’s nutritional value, per the FDA, and reclosable pouch packaging offers a convenient seal that is easy to open and close while keeping food fresh. Using premium closure features like zippers with an enhanced audible snap and solid touch as they close gives consumers confidence that the package is properly sealed. When food stays fresh longer, consumers save money by avoiding product waste, and they have all of the product information readily available in case of a product defect or recall.

4. Flexible Packaging Provides Sustainability Benefits

Flexible packaging offers many sustainability benefits for both brands and consumers. For brands, recyclable closures that feature enhanced sealant layers can adhere easily to sustainable film structures, allowing for fully recyclable packaging options. These flexible packages help lower carbon emissions, water and fossil fuel usage, and materials to landfill throughout their life cycle. Additional manufacturing benefits for brands include protection from film distortion and faster converting cycles, thanks to easy zipper crush locks that require minimal heat for sealing.

These environmental benefits can be easily communicated to consumers who will enjoy supporting a brand that cares about the environment and provides an opportunity for pet owners to contribute to a circular economy.

More Convenience, More Customers

According to data from IRI All Outlet Panel, nearly 7-in 10 households have purchased pet food and treats in the past year. Combine that with the knowledge that approximately 60% of dog and cat owners are concerned about their pet’s nutrition (FINN CADDY), and you get a substantial consumer segment that wants quality products for their pets.

Premium pet food brands do not have to sacrifice packaging convenience and functionality to attract customers. In fact, providing safe, sustainable and user-friendly options at a premium communicates the value your product offers. And, using innovative packaging features and designs lets pet owners know they are buying only the best for their best pals.

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