Innovation in packaging has been seen to come up with flexible packaging that has transformed the storage, transportation, and even access to food and other consumer products. But this is where it all began and the company has humble roots. The first recorded flexible packaging materials are things like leaves, animal skins and the likes. Alternatively, the use of paper started thousands of years ago as a primary way of wrapping items. Latterly, tin foils and parchment papers, glassine, wax papers, etc. were used as the initial forms of flexible packaging to keep food items. These materials proved to be more durable and possess enhanced barrier properties as compared to natural materials.
This paper focuses on the onset of two products namely plastics and foil.
The onset of plastic films are a polymer which was developed in the early 20th century. Cellophane was among the first flexible packaging material from the processed cellulose. Later on, low density poly ethylene (LDPE) high density poly ethylene (HDPE) and other plastic films were option which are used for the flexible packaging. Their cost-effectiveness, tensile strength, and effectiveness in preventing moisture and air ingress made them ideal for use in food packaging such as breads, snacks etc. These retard films also became popular since they offered improved protection for food and could also be used in conjunction with papers and plastics.
Bag-In-Box Packaging Game Changer
Flexible Packaging bag-in-box was another revolutionary packaging idea that came in to utilization in the 1960s for the containing of liquid products like juices and wines. It comprised of, a hard black corrugated box that contained a thin polyethylene bag with a faucet on it. This made it easier to transport and protect the liquids as it was a lightweight design which made it easy to open to access the contents. The bag also comes with a fold down feature to reduce the contact with the product when dispensing the product thus reducing contamination. Compared to more conventional packaging such as glass bottles or metal cans, Bag-In-Box packaging also helped to decrease packaging weight, the price of packaging, and the amount of storage space needed. This made flexible packaging an amazingly valuable innovation, particularly with regards to making, delivering, and utilizing sustenance items.
Barrier Films Advancements
When flexible packaging started to become more widespread especially for food and other consumable products, efforts were made to improve the barrier properties thereof. Some of the well-known films included nylon and EVOH (ethylene vinyl alcohol) which provided good barrier against oxygen, chemicals and aroma. Aluminum foil was used for light and UV barriers and the metallization and films offered an improved vapor barrier. Laminations and coatings merged characteristics of various materials into one versatile film that has high barrier properties for moisture, gases, light, as well as temperature. High barrier flexible packaging significantly contributed to an extended food shelf life and enhanced convenience such as microwaveability, as consumers’ lifestyles evolved.
The Economic and Environmental Impacts of Bio-Based Films
A consequence of this development was that multi-layer and mixed-material flexible packaging films became a problem with respect to sustainability because of their recyclability. This led to regulatory and consumer environmental interests to be created to bring out other forms of flexible packaging like the PLA from renewable resources such as corn starch and Mater-Bi from vegetable oil. These bio-films offer adequate levels of clarity and coverage, but are biodegradable in addition. Of course, certain matters such as lower maximum temperature thresholds have hindered a complete replacement of conventional films up to now. Innovation follows the same trend with a particular emphasis placed on strength as well as barrier properties enhancement.
Smart Packaging and Active Packaging are terms that refer to packaging technologies that have an ability to sense what is being packaged and respond accordingly.
The sub-categories that have emerged from it are the smart flexible packaging and the active flexible packaging. Intelligent packaging allows for communication of information regarding the contents of a pack, such as integrated time temperature indicators for perishable goods. Active packaging releases preservative elements such as oxygen absorbers to maintain freshness, flavor, and texture of food. Antimicrobial releases prevent the formation of bacteria and mold formations on the material. Rather than simple protective casings, these smart flexible packages have the potential of having multifunctional flexibility. Tags based on RFID or quick-response (QR) codes offer far greater possibilities in terms of traceability and anti-counterfeiting.
Stand-Up Pouches Make Waves
Among the latest flexible packaging formations, the stand-up pouch has gained quite a following. Compared to conventional pouches and bags, stand-up pouches are pouches that can actually be able to stand on their own on shelves. Usually, it is produced by piling several films and are well protective with the additional graphics shaped like a box. Doypacks also refer to a stand-up pouch which has two sections for the purpose of ensuring that moist and dry foods are not mixed. While the second and third types can typically be made from the same materials as stand-up pouches, spouted pouches provide an additional degree of convenience through liquid dispensing. The size of the stand-up pouch market was 24. 5 billion USD in 2020 and is forecasted to grow continuously through 2028, proving this new packaging style’s popularity.
Flexible Packaging: A Future Outlook
The enhancement of flexible packaging capabilities even today with technical advancements is also noted to have a slight negative effect on the environment. Growing segments such as enzymes and marine biodegradable films, nano packaging with active antimicrobial layer, micro vents, and dissolving films offer better functionality. Recycling enhancement and the use of higher recycled products are also steps toward the achievement of circular economy objectives. Consequently, flexibility in packaging will go on advancing as active and smart properties are introduced alongside improving sustainability efforts.
In the course of history, flexible packaging has brought about change that has reached the aspects of storage, distribution, accessibility, and preservation of food and products. Originally coming from leaves and skin, with the help of materials technologies and innovation, we have come up with this smart packaging that tends to suit every lifestyle we are in today. It is difficult to even contemplate where the future waves of development will lead flexible packaging from the current stage. The packaging that is used for the consumer products is also likely to follow the same changes to reflect the kind of packaging that is relevant in today’s market.
