What is barrier packaging and why does it matter so much?
Barrier packaging refers to films and laminates designed to limit the permeation of gases (particularly oxygen), water vapour and odours. Their effectiveness directly affects:
• the shelf life and freshness of the product,
• quality stability throughout the supply chain,
• microbiological safety,
• the reduction of losses and complaints.
In practice this means that even small changes in the material structure can have a real impact on the quality of the finished product.
Barrier packaging in the context of material change
Traditionally, high barrier performance was achieved by using multi-material structures such as PET/ALU/PE. Now, with the development of mono-materials and recycling requirements, barrier packaging has to be designed more consciously and precisely.
This means the need to:
• optimise the material structure,
• control film thickness,
• apply barrier coatings,
• confirm the parameters through laboratory testing.
Without this, packaging may meet the formal requirements but fail to provide adequate product protection over a longer period.
Measuring barrier performance as the basis for designing barrier packaging
At Mardruk Opakowania, the design of barrier packaging is based on systematic testing carried out by our R&D team. A key element of this process is precise measurement of oxygen permeability (OTR – Oxygen Transmission Rate).
For this purpose we use specialist MOCON OX-TRAN equipment, which allows us to:
• determine the material's barrier level accurately,
• compare different laminate and film structures,
• assess the impact of material modifications on product protection.
This makes it possible to design barrier packaging based on data rather than assumptions.
Which factors affect the effectiveness of barrier packaging?
Barrier testing covers the analysis of many technical parameters, including:
• the material structure of the laminate,
• the thickness of the individual layers,
• the type of barrier coatings used,
• the uniformity of the material,
• the impact of production processes on the final OTR value.
This approach makes it possible to optimise barrier packaging precisely, including in next-generation solutions.
Barrier packaging and the stability of production and logistics
From the point of view of procurement and production departments, barrier packaging serves as a risk-management tool. A thoroughly tested material makes it possible to:
• predict its behaviour on packaging lines,
• reduce the risk of downtime,
• ensure repeatable quality,
• assess the product's shelf life in transport and storage.
This is especially important for products sensitive to oxidation and for long supply chains.
Summary – barrier packaging as part of conscious design
At Mardruk, barrier packaging is treated as an integral part of product protection, not merely a carrier for graphics. Thanks to the work of our R&D team and the use of modern laboratory equipment, we create solutions that:
• provide real protection of the contents,
• increase product shelf life,
• meet the growing requirements of regulators,
• are stable and predictable in series production
• Order a free consultation and specification (substrate, activation, perforation).
• Order samples and a pilot run.
• Get a fast quote and a delivery plan that keeps to the calendar.
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Frequently asked questions
Barrier packaging refers to solutions designed to protect the product effectively against external factors such as oxygen, moisture, light and odours. Thanks to a well-chosen material structure, it helps maintain the quality, freshness and shelf life of the product.
Barrier packaging is used above all in the food, cosmetics, pharmaceutical and chemical sectors. It is used wherever a product needs increased protection during storage, transport and sale.
The most important advantage of barrier packaging is the high level of product protection against the adverse influence of the external environment. In addition, it helps extend product shelf life, improves storage safety and better matches the packaging to the specifics of a given sector.
Barrier packaging can protect against, among other things, the ingress of oxygen, the permeation of water vapour, aroma loss, the effect of light and external contaminants. The scope of protection depends on the materials used and the construction of the packaging.
The choice of barrier packaging should take into account the type of product, its sensitivity to external factors, the required shelf life and the storage and transport conditions. A well-designed packaging structure makes it possible to protect the product better and preserve its properties.
Sounds like your project?
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