Material selection directly affects the look, barrier performance, and cost of flexible packaging.
Most flexible packaging ((including mylar bags, lay flat pouches, gusseted pouches, and more) uses a laminated structure.
A typical packaging layer breakdown, from outside to inside, is:
Printing Layer → Barrier Layer → Heat-Seal Layer
The barrier layer can be one layer, two layers, or even omitted, depending on your product’s specific needs.
Below is an overview of common films used at Pouching and their key characteristics:
Outer layer (printing layer)
BOPP
Thickness: 0.015 – 0.030mm (0.6 – 1.2mil)
Features: High clarity, strong barrier, excellent moisture resistance.
Matte BOPP
Thickness: 0.015 – 0.030mm (0.6 – 1.2mil)
Features: Premium matte finish, high barrier, excellent moisture resistance.
Holographic BOPP
Thickness: 0.015 – 0.030mm (0.6 – 1.2mil)
Features: Vibrant holographic effect, strong visual impact, high barrier, excellent moisture resistance.
PET
Thickness: 0.012 – 0.025mm (0.5 – 1.0mil)
Features: High clarity, high stiffness, strong barrier, excellent oxygen resistance.
Matte PET
Thickness: 0.012 – 0.025mm (0.5 – 1.0mil)
Features: Premium matte finish, high stiffness, strong barrier, excellent oxygen resistance.
NY
Thickness: 0.015 – 0.025mm (0.6 – 1.0mil)
Features: Good printability, excellent oxygen barrier, poor moisture resistance, outstanding puncture resistance.
PLA
Thickness: 0.020 – 0.030mm (0.8 – 1.2mil)
Features: Compostable, high clarity, average barrier performance.
NK
Thickness: 0.019 – 0.045mm (0.75 – 1.8mil)
Features: Plant-based compostable, high clarity, strong barrier, high static electricity.
Mdo-PE
Thickness: 0.020 – 0.040mm (0.8 – 1.6mil)
Features: Higher stiffness than regular PE, printable, good moisture barrier, low oxygen barrier.
Kraft Paper (Brown/White)
Thickness: 0.05–0.075mm (2–3mil)
Features: Plant-fiber based, compostable, high stiffness, good printability, low barrier. Suitable for eco-friendly packaging.
middle Layer (barrier layer)
BOPP
Thickness: 0.015 – 0.030mm (0.6 – 1.2mil)
Features: High clarity, strong barrier, excellent moisture resistance.
Metallized BOPP
Thickness: 0.015 – 0.030mm (0.6 – 1.2mil)
Features: Excellent light blocking, ultra-high barrier. Much better moisture and oxygen resistance than plain BOPP, especially outstanding moisture barrier.
BOPP Alox
Thickness: 0.015 – 0.030mm (0.6 – 1.2mil)
Features: BOPP film coated with a dense silica layer. High clarity, ultra-high barrier. Significantly better moisture and oxygen resistance than plain BOPP.
PET
Thickness: 0.012 – 0.025mm (0.5 – 1.0mil)
Features: High clarity, high stiffness, strong barrier, excellent oxygen resistance and aroma retention.
Metallized PET
Thickness: 0.012 – 0.025mm (0.5 – 1.0mil)
Features: Excellent light blocking, ultra-high barrier. Much better moisture and oxygen resistance than plain PET, especially outstanding oxygen barrier.
PET Alox
Thickness: 0.012 – 0.025mm (0.5 – 1.0mil)
Features: PET film coated with a dense silica layer. High clarity, ultra-high barrier. Significantly better oxygen and moisture resistance than plain PET, with excellent aroma retention.
NY
Thickness: 0.015 – 0.025mm (0.6 – 1.0mil)
Features: Excellent oxygen barrier, poor moisture resistance, outstanding puncture resistance. Ideal for vacuum packaging and sharp-edged products like nuts.
Aluminum
Thickness: 0.006 – 0.012mm (0.25 – 0.5mil)
Features: Highest barrier among all films. Complete protection against oxygen, moisture, odor, and light. Perfect for long-shelf-life products and pharmaceuticals with extreme barrier needs.
Mdo-PE
Thickness: 0.020 – 0.040mm (0.8 – 1.6mil)
Features: Higher stiffness than regular PE, printable, good moisture barrier, low oxygen barrier.
Kraft Paper (Brown/White)
Thickness: 0.05–0.075mm (2–3mil)
Features: Plant-fiber based, compostable, high stiffness, good printability, low barrier.
Inner Layer (Heat-Seal Layer)
PE (including CPE, LDPE, LLDPE, mPE)
Thickness: 0.04–0.10 mm (1.6–4.0 mil)
Features: Wide heat-seal window, supports manual or high-speed automatic sealing, high seal strength, strong impact resistance, good low-temperature resistance, excellent anti-contamination sealing performance.
Suitable for powder, sauce, and paste products. Good moisture barrier, low clarity, low stiffness, poor oxygen barrier, low heat resistance, poor oil resistance.
CPP (including RCPP, VMCPP)
Thickness: 0.04–0.10 mm (1.6–4.0 mil)
Features: High clarity (except VMCPP), good scratch resistance, better display effect, higher stiffness, higher sealing temperature, ideal for high-speed automatic sealing, good oil resistance, high heat resistance, suitable for retort packaging.
Poor low-temperature resistance, lower seal strength and anti-contamination performance than PE, good moisture barrier, poor oxygen barrier.
PLA
Thickness: 0.02–0.06 mm (0.8–2.4 mil)
Features: High clarity, good gloss, made from corn starch, suitable for compostable packaging, good stiffness, poor heat resistance, low impact resistance and flexibility, narrow heat-seal window, moderate seal strength.
PBS
Thickness: 0.03–0.08 mm (1.2–3.2 mil)
Features: Compostable, good flexibility, better mechanical strength and heat resistance than PLA, good heat-seal performance, ideal as seal layer in compostable structures.
Good oil and chemical resistance. Moderate clarity, higher material cost, average oxygen and moisture barrier.
PBAT
Thickness: 0.02–0.06 mm (0.8–2.4 mil)
Features: High softness, excellent ductility and tear resistance, biodegradable, often used to improve flexibility in eco-friendly structures.
Good sealability, good low-temperature resistance. Average clarity, low stiffness, average heat resistance, weak barrier properties.
Summary
That’s all for our detailed introduction to flexible packaging materials.
Pouching is a supplier specializing in high-quality custom flexible packaging solutions, and we are here to support your packaging needs.
If you have any questions, feel free to contact us at any time.
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