The materials used in food-safe flexible packaging have evolved dramatically over the past decade. What used to be a relatively simple choice between a few standard laminates has become a much more sophisticated decision involving performance, food safety, recyclability and cost.
Here are some of the key material innovations that are shaping the next generation of flexible packaging — particularly relevant for South African food manufacturers.
High-Performance Barrier Polymers
Traditional EVOH remains the workhorse for high oxygen barrier, but newer generations offer:
- Better thermoforming properties for deep-draw applications
- Improved humidity resistance (critical in parts of South Africa)
- Lower thickness for the same barrier performance (cost and sustainability benefit)
Specialised polyamide (PA) grades and advanced tie-layer resins are also enabling thinner, more functional structures without sacrificing performance.
Mono-Material Structures for Recyclability
One of the biggest shifts is the move toward mono-PE and mono-PP structures that can be recycled in existing streams.
Key developments include:
- High-barrier PE films with EVOH or new nano-barrier coatings that remain recyclable
- All-PE stand-up pouches with acceptable stiffness and optics
- Recyclable barrier lidding films for thermoformed trays
These structures are no longer theoretical — they are being commercialised on real filling lines in South Africa.
Functional Coatings and Surface Treatments
Instead of adding another layer of film, many manufacturers are using advanced coatings to deliver specific properties:
- High-barrier coatings (oxygen, moisture, aroma)
- Easy-peel and reclosable coatings
- Anti-fog coatings for fresh produce
- High-temperature resistant coatings for hot-fill or retort applications
Coatings often allow significant downgauging while maintaining or improving functionality.
Bio-Based and Compostable Options
While not suitable for every application, bio-based and industrially compostable materials are gaining traction in specific categories (fresh produce, coffee, certain snacks).
South African brands need to be realistic about local composting infrastructure, but these materials are becoming part of a broader sustainability toolkit.
What This Means for South African Brands
When evaluating new packaging structures, consider:
- Does the material deliver the required shelf life under real South African distribution conditions?
- Is it compatible with your existing filling and sealing equipment?
- Can it be printed to the required quality at acceptable cost?
- Does it support your EPR and sustainability commitments?
The most successful projects combine material innovation with practical converting capability. A great structure on paper is useless if it cannot be produced reliably and affordably at scale.
At Flexweb we work closely with customers to evaluate new materials on our own production lines before committing to full-scale production. This hands-on approach significantly reduces risk when moving to new structures.
Discuss your next packaging development project →
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