What Are Barrier Films And How Are They Used?

While the average consumer might not think twice about how barrier films are used and what makes them unique, companies in the food industry and other competitive markets rely heavily on these types of materials.

Let’s explore what barrier films are, how they’re used, and the different types of materials we see used throughout industries including food, medicine, and mechanical components.

What Is a Barrier Film?

Since its applications are so wide-reaching, a barrier film is mainly defined by its material and its thickness. Films generally range between .06 mm and .25 mm, while anything thicker than that is categorized as a sheet.

Barrier films also tend to be made from plastic, although modern variations may include metallized materials that change colors. Because the layers are so thin, they can be customized and fitted with extreme precision, allowing manufacturers to create proprietary solutions for individual products.

Flexibility paired with strength and stability help form superior films that make all the difference in production.

This results in a product that not only looks and feels high-quality, but also has visual appeal (in-store or online), protects against elements like moisture and gas, and provides a workable canvas for branding, labeling, and differentiation.

All these factors combine to make barrier films a vital component in modern packaging and production, especially with perishable food products and other consumables.

What Are OTR and MVTR?

When comparing barrier films for food packaging, oxygen transmission rate (OTR) and moisture vapor transmission rates (MVTR) are the two main metrics to note.

OTR measures how much oxygen gas passes through a barrier film over a certain period of time, while MVTR measures how much water vapor passes through. These are relevant metrics for a wide array of applications from industrial and construction settings to the manufacturing of snack foods, household items, and other consumables and devices.

Both measurements are worth tracking due to the interaction of oxygen and moisture with various products, particularly over long periods of time. Two days of shipping or time spent in storage may not impact a product’s appearance or quality, but what about two weeks, two months, and beyond? These extended durations are when barrier films matter most.

To maintain peak product quality, manufacturers must source barrier films that not only maximize OTR and MVTR in the short term but also limit permeability over time (even under high temperatures and humidity) and ensure a good user experience once the product is in use.

What Are the Different Levels of Barrier Films?

With limitless variations of barrier films available, it helps to categorize these products into levels based on strength and performance. Here are the basic levels of barrier films, typical materials, and the properties they’re known for in common applications.

Basic: Single Layer

Not much protection can be expected from a single-layer barrier film, but these materials can get the job done in many short-term food service applications, such as self-adhesive “cling film” made from soft polyvinyl chloride (PVC).

Polyethylene film (also known as shrink wrap), polyamide (nylon), and other single-layer films are quick and accessible at home. These products tend to fall short with large-scale transport, shipping, and storage.

At most, you may see an interior single-layer film used for individually-wrapped products in cardboard containers or tins, but they don’t serve as a primary protective layer.

Basic: Double Layer

With PVC or polyethylene as a common base, another film can be thermoformed on top of that initial layer to create a more stable material with superior properties.

This is how producers achieve a better balance of impermeability to both moisture, oxygen, and even temperatures — which can’t be accomplished by a single layer film alone.

For example, oxygen-proof polyamide combined with water-vapor-proof polyethylene will create an ideal double-layer film that can better protect food products and withstand harsher conditions for longer durations.

The advantage here is that double-layer films are still lightweight and highly flexible, morphing to the dimensions of a product and permitting transparency. However, these films can’t be classified as high-performing, and aren’t recommended for large-scale transport and storage.

Moderate

Examples of moderate barrier films may include polyethylene terephthalate (PET), oriented polypropylene (OPP), or biaxially-oriented polypropylene (BOPP). These films offer strong barrier properties, including better moisture and oxygen protection, along with better labeling capabilities.

These films also have a better look and feel that can compete for consumer attention on store shelves. What’s more, they can deliver a good user experience after purchase.

Customization options are greater, packaging prices are reasonable, and orders can be executed at scale, making these good intermediate options for food products, and other consumables.

High Performing

At the top of the range for barrier films are high-performing materials made from multiple layers and including modern industrial additives and treatments.

The result is a highly customized end product, engineered with precision in the exact specifications of the producer.

What Are Examples of High-Barrier Films?

Popular high-barrier films are now more accessible, customizable, and affordable for producers in the food industry and beyond. Here are some of the best-performing barrier films available now and what properties they offer.

Ethylene-Vinyl Alcohol (EVOH)

A leader in oxygen barrier properties, EVOH is used to keep food and beverage items fresh, as well as medical products and cosmetics. EVOH works best in a layered configuration between an HDPE outer wall and an adhesive resin such as polyamide on either side.

This setup is found in many plastic bottles and jars, maximizing protection against a full range of gases and humidity while regulating temperatures.

Metallized Polyester (Mylar, VMPET, BOPET, & METPET)

A modern upgrade to aluminum foil, metallized polyester materials give you the best of both worlds in terms of thin thermoplastic films and superior barrier properties..

This combination is achieved by coating a polymer film with a thin layer of metal, giving the material a glossy metallic finish while enhancing oxygen and moisture barrier properties and retaining lightweight flexibility.

Mylar is a popular version of this high-performing film, used in electronics circuits, snack and coffee packages, decorations, and insulation.

Nylon (NY6)

Nylon film (a thin form of polyamide) is tough. It’s resistant to scratches, punctures, and flex-cracks, all of which can negatively impact the look and feel of products on the shelf.

Producers also have access to a wide variety of nylon film types, based on what they need in terms of barrier properties and visual attributes.

PVDC (Polyvinylidene Chloride)

PVDC excels in protecting products from vapor, moisture, and oxygen, and is often combined with other layers for increased effect.

On its own, PVDC is still a high-performance barrier film with great tensile strength, ideal for delicate and perishable products with see-through packaging.

Why Are Food Barrier Films Popular?

Food producers aim to bring products to market with speed, stability, longevity, and a degree of visual appeal to catch consumers’ attention and encourage a purchase.

Only the best barrier films allow for all these factors to be balanced simultaneously, which explains why companies seek high-performing materials from trusted partners.

The right barrier film selection could lead to record-setting sales and customer satisfaction, making it a critical part of the production decision chain.

The Bottom Line

There’s a specialized film for any application you can imagine, from shipping televisions to developing the best package for snacks or medicine. At Dymapak, these films can be customized to your exact specifications, boosting product quality to help keep your customers happy.

Choose the right barrier films and utilize the perfect package for products that arrive safe and sound.

Sources:

Global Barrier Films Market | Data Bridge Market Research

Understanding Barrier Films for Flexible Packaging | Labels and Labeling

The Barrier Film Breakdown | Inteplast Group

Qingdao Kingchuan- Kingchuan Packaging

BOPP film is the most in-demand packaging material due to its flexibility and durability. Its strength, versatility, and outstanding mechanical properties make it the best among others. Moreover, what if the packaging material is also cost-effective and eco-friendly?

These are the added perks that make you inclined towards buying a specific packaging material. Amazingly, global BOPP film manufacturers facilitate you with these benefits.

Let’s have a look at the reasons for the popularity of polypropylene films!

Reasons

Amazing properties and benefits

Wide variety of BOPP film rolls

Compatible with countless industries

Decorative purposes

Printability

Edge over paper packaging

Distinctive polypropylene-based film

Environmentally Friendly

BOPP Films Properties & Advantages

They are flexible. Therefore, you can wrap them on various products.

They are water, heat, and chemical resistant.

Food-grade polypropylene films are safe for health.

Above all, they are recyclable and eco-friendly.

BOPP plastic films are lightweight and also easy to wrap.

Equally important, these films increase the shelf life of edibles.

To conclude, BOPP films are cost-effective, strong, versatile, and durable.

Figure 1 Food Grade BOPP Film

BOPP film rolls possess the following astonishing characteristics:

Heat sealable

Ideal surface gloss

Moisture-resistant

Anti-static

Low toxicity

Anti-fogging

Printable

Extended shelf life

Solvent & acid-resistant

Durable

Due to the increasing controversies against the use of plastic, plastic has become taboo. Authorities have banned single-use plastic. To overcome this problem, global BOPP film manufacturers use polypropylene as their raw material. Polypropylene emits the lowest carbon dioxide in contrast with other plastics.

BOPP film manufacturing process is also safe for the environment. This process uses less energy. As the emphasis on energy conservation is increasing, BOPP is taking over conventional (plastic) packaging.

Moreover, BOPP is among the recyclable materials. Therefore, BOPP film manufacturing process takes place without toxic emissions, halogens, or toxic wastes. Thus, causing no hazardous effect on the environment.

The Manufacturing Process of Bopp Film

BOPP is a multi-layer film having polypropylene at its core with several additional layers. When polypropylene is orientated in two directions, it guarantees that the resulting BOPP film has excellent mechanical properties and durability in both these directions

Layers of BOPP film may also contain a combination of appropriate functional additives and polymers that determine its barrier properties, whiteness, opacity, gloss, or matting. So, the manufacturer is in complete control of film properties.

A BOPP film can be produced by several methods but three processes are most commonly used. These include the Tubular process and Tenter Frame Sequential process.

1)Tubular Process

In this process, BOPP film manufacturers create the sheet by extruding a thick plastic tube. After that, the tube passes through the stretching heaters and inflates into a tubular bubble.

Then the bubble is compressed, and the lay-flat stretches and gives the sheet its required thickness. Nevertheless, this process is not as commonly used as the tenter frame process.

Figure 2 Tubular Process

2)Tenter Frame Process

In this BOPP film manufacturing process, a thick plastic sheet is softened at a low temperature. Then it is 300 – 400% stretched in two directions.

There are two methods for the biaxial orientation – simultaneous or sequential. In the tubular process and some new-technology tenter frame processes, simultaneous orientation forms BOPP sheets.

However, most commonly, BOPP film manufacturers use sequential orientation to form polypropylene films.

Figure 3 Tenter Frame Process

Polypropylene Film Types

BOPP is available in many types. Namely:

Clear BOPP Plastic Film

These transparent films are most commonly used for food packaging, for example, pulses, nuts, fresh fruits, vegetables & meat, cookies, etc.

Pearlized BOPP Film

Ideal for printing and is a perfect inner sealant for products like chocolate, ice cream, and labels for soda drinks.

BOPP Thermal Lamination Film

It is an ideal solution for two-sided printing. These films are usually used for brochures, shopping bags, textbooks, leaflets, etc.

Matte Polypropylene Film

This film is also suitable for printing. It is appropriate for cable wrapping, printed pouches, and strip packaging.

Printable White BOPP Film

White BOPP plastic film gives fantastic printing results. Also, the fast colors with accurate printing enhance the quality of pouches and labels.

BOPP Film for Adhesive Tape

The versatile properties of BOPP plastic make it adequate for coating and printing. Therefore, manufacturers prefer using these films to create self-adhesive tapes. Furthermore, you can custom-print these tapes as well.

Heat Sealing Film

These films are a perfect solution for applications that require solid and durable sealing. You may get variations in the sealing properties. Some may seal at low temperatures, while some may give you the flexibility to clinch a single side.

Figure 2 White BOPP Film Packaging

BOPP Films Applications

BOPP films are widely used in the packaging industry. If we see in a broad spectrum, they are suitable for:

Bags and pouches

Labels

Wrapping

Adhesive tapes

Let’s elaborate on these four categories. For instance, polypropylene films are functional for:

Packing personal care products 

Tamper evident films

BOPP labels

Adhesive tape

Food and beverage packaging

Cigarette packaging

Medical packaging

Lamination

Decorative and industrial applications

Gift wrapping

Flower sleeves

Bagging

Figure 3 Flexible Packaging with BOPP Film

How to Print a BOPP Film?

BOPP films are incredibly versatile and that’s what makes them so good for printing labels. They can be simply white, clear, or transparent, and even metal-colored. With clear BOPP film, transparent labels can be easily created. These are ideal for businesses that want to show the contents of their products with clear containers. By using certain adhesives and inks, BOPP labels can be made waterproof.

The recommendations to print a polypropylene film are:

Flexography printing

Rotogravure printing

Lithography printing

Choosing a specific printing technique depends on your budget, material, design, and graphics.

King Chuan Packaging facilitates you with numerous BOPP plastic films. Therefore, you can choose the best-suited printing method to print your particular BOPP film roll.

However, the most common printing technique that gives you the best results is flexography printing.

Be creative! Print your BOPP Films Label to Captivate the Buyer’s Attention

Another reason behind the increasing popularity of BOPP film rolls is their printability. Beautifully printed BOPP labels are an ideal solution for brands to promote their name.

Purpose of Labels

Consequently, brands use BOPP labels to:

Promote their name

Showcase company’s contact details

Beautify the packaging

Captivate buyer’s attention

Provide you with the product’s specifications

Figure 4 Printed BOPP Labels

Types of BOPP Labels

These labels can be:

White

Metallized 

Transparent or opaque

Flexible and squeezable (for tubes)

Not only labels, but you can get printed plastic bags, pouches, wraps, and tapes as well.

Customized BOPP Labels

Do you want customized prints on the BOPP labels?

It is not a big deal. BOPP film manufacturers facilitate you with the opportunity to have custom-made labels.

You can have your brand name, product details, and contact information on the label. As a result, this label is a promotional tool for your brand.

Difference between Paper and BOPP Film Packaging

There are two types of BOPP film manufacturing processes – tubular or tenter frame process. In both methods, the BOPP film manufacturers stretch the film in two directions to make it strong, tensile, and durable.

On the other hand, paper is not as flexible and robust as plastic.

Secondly, polypropylene film is resistant to water, oil, and chemicals. In contrast, paper cannot resist fluids.

A BOPP film is scratch and wear-resistant, unlike paper.

Is Bopp Film Recyclable?

Yes, the Biaxially oriented polypropylene film is recyclable. They have a low density yet excellent stiffness that allows for thin yet durable BOPP films. While recycling, it doesn’t degrade as much as other films. BOPP films can be easily recycled by mixing them in a polypropylene recycling stream. Almost every product made from polypropylene (including BOPP) can be recycled into polymer pallets that can be used for a variety of industrial and commercial applications.

Advantages of Choosing Our Recyclable Packaging Films:

It Protects the Environment: Our recyclable BOPP film packaging is good for the environment as it helps in preserving our precious natural resources. Not only can recyclable BOPP films meet your financial goals, but they can also help you contribute to the environment.

Ensures That the Packaging Is Free of Toxins and Allergens: Traditional packaging materials are manufactured from chemical-laden and synthetic materials that are unhealthy for the consumers as well as harmful for the manufacturers. Our BOPP film packaging is completely non-toxic and free of all types of allergens.

Stunning, Durable, and Eco-Friendly Bopp Films Can Lead to Increased Sales: The demand for eco-friendly products has been growing for the last few decades. Today’s environmentally conscious consumers prefer eco-friendly products that do not harm their health and the environment in any way. Choosing stunning and durable BOPP films for your packaging needs can help you attract more customers to your business.

BOPP Packaging Films Are Flexible and Versatile: Eco-friendly BOPP films are some of the most versatile packaging options out there. They can be easily recycled to be used in many other industries. Whether you want a perfect film for medical packaging or personal care product packaging, there will be a suitable BOPP film to meet your packaging needs.

Our Highest Quality BOPP Films Can Help Enhance Your Brand Image: Having high-quality eco-friendly packaging material like BOPP films on the products can help you create a good brand image for your business. This will also show the customers that they are dealing with a responsible company that cares about the environment.

Upcoming Trends for BOPP Films

The rapidly growing packaging industry is increasing the demand for packaging material.

Because of its extraordinary qualities, BOPP plastic film is taking over traditional packaging materials (metal and paper).

Furthermore, the packaging industry prefers using polypropylene films as they are easy to use and lightweight.

According to recent research, the international market demand for BOPP film was $24.2 billion in 2020. It is projected that, by 2025, it will grow to $31.4 billion.

Hence, these statistics show that investing in the plastic industry is profitable. Indeed, your business will get a boost by dealing in eco-friendly BOPP plastic film rolls.

For example, if you are related to food packaging, BOPP is an appropriate solution for you. Highly sterilized BOPP films are food safe. Additionally, they prevent food from contamination.

These easy to wrap films are widely used for pet food, baby food, frozen meals, etc. Briefly, your investments are secure while dealing with polypropylene films.

Figure 5 Food Packaging with BOPP Film

Final Verdict

As mentioned, BOPP films cover all the aspects of life, so it is eventually the best choice! We are positive that now when you know a long list of benefits of polypropylene film, your next choice in business or daily chores will be BOPP films. Get started right away, and don’t miss out on these fantastic compensations.

Exploring the Different Kinds of Flexible Packaging Films

One of the most important steps of any food or beverage production process is how they will be packaged. As a manufacturer, you need a strong package design to protect the product from damage, catch your customer’s attention, and retain their interest. 

While that may seem like an overwhelming goal, it’s possible thanks to the many benefits of flexible packaging design available. While traditional packaging has bulky and costly limitations, flexible packaging films can fit nearly any product in almost any industry. 

Are you using the best flexible packaging design for your products? Explore the different types of flexible packaging films to influence your next product packaging design.

What Is Flexible Packaging?

Unlike rigid packages, flexible packaging earns its name from its flexibility since the shape is based on the product design. Thanks to this, flexible packaging is a versatile and functional solution for your products and can seamlessly be made out of several materials for added performance results. Some great examples of flexible packaging include:

Sleeves

Pouches

Bags

Shrink films

These products are made from either film, foil, plastic, paper, or a combination of a few to meet the manufacturing and distribution needs in a stylish and attention-getting way.

More and more businesses are turning to flexible packaging designs for their durability, affordability, high-quality materials, and FDA-approved ability to increase shelf life. Custom tailor it to fit any product, regardless of shape or size. On top of everything else, flexible packages provide the perfect landscape for designers to create attractive and engaging designs.

Stand Up Pouches

This is one of the best alternatives to standard packaging. Many companies have shifted to using stand-up pouches since they stand up on shelves in stores. On top of this stand-out design, it also provides an airtight seal to help with preserving the product. Customers also love these flexible packaging designs due to their ease of use and eye-catching graphics. Depending on what you want packaged, select from either single or multi-layer films for extra protection.

Lay Flat Pouches

As the name suggests, lay flat pouches are designed with a flat design so they either rest on surfaces or hang from hooks on wall displays with the addition of implanted hang holes. Do you regularly dispatch customers’ orders? If so, lay flat pouches offer a unique design advantage for this service since they are lightweight and compact. Reduce your waste and maximize your storage space with this design.

Types of Flexible Packaging Film

Plastic polymer packaging materials are widespread and commonly used due to their affordability and flexibility. Each type of plastic has signature properties that make it highly desirable for food packaging. Don’t forget that working with a skilled packaging designer will help you save time and money by ensuring you get the best product packaging solution. Shop our selection of flexible packaging film solutions to find the perfect fit for your product.

Explore the different flexible packaging films offered by The Package Lab, including:

Barrier Clear: These

clear pouch films

offer excellent barrier properties, ink adhesion, and puncture resistance. 

Barrier White: Looking for a durable pouch application? Select white pouch films for their puncture resistance, quality barrier control, and good adhesive bonds.

Clear Snack Web: Choose this

medium gauge clear film

for snacks thanks to its durable sealant layer, economical packaging, and heat stability.

White Snack Web: If you want all the benefits of a clear snack web without clarity, select the medium gauge white film for snack pack applications.

Metalized Barrier Snack Web:

Metalized pouch films

continue the benefits of heat stability, excellent barrier properties, and durability. 

BOPP Clear: This film is treated on one side with Ultra High Surface Energy (UHSE) for a safe heat seal layer. Consider thin gauge clear film for numerous applications.

Materials Used for Flexible Packaging Film

What would product design be without the materials used to create it? Read on to learn more about the most common types of plastic polymer flexible packaging film types:

BOPA

Biaxially-oriented polyamide, a.k.a BOPA, is most commonly used for distilled goods, perishable food, and some agricultural products. This is because it’s exceptionally durable and puncture-resistant while still retaining a high level of transparency. 

If you need to know what’s inside without worrying about its tensile strength, consider this strong barrier against oxygen, aromas, and even some chemical substances. Take a peek at some great uses for BOPA packaging below:

Vegetables

Frozen foods

Electronics

Medical machines

And more

BOPP

Similar to BOPA, this extruded bi-axially orientated polypropylene polymer (BOPP) is an excellent flexible packaging option for many food sources.  Due to its resilience and clarity, BOPP is used in snack food packages, especially because it can hold weight without easily breaking. You can even use BOPP in packaging labels. Since it locks out moisture, it can even be an excellent selection for pesticide, hygiene, dairy, or confectionery packing. See some great examples below:

Rice

Minerals

Pesticides

Bird seeds

Personal hygiene products

Pharmaceuticals

Pet foods

BOPET

Biaxially-oriented polyethylene terephthalate (BOPET) builds off of the strength and oxygen-blocking qualities of the previously mentioned polymers to create a stiffer barrier. BOPET’s high tensile strength combined with added heat resistance allows it to withstand modifications without compromising the food’s aroma or flavor.

As a result, you can find this polymer throughout the food industry, especially as the lids of ready-made frozen dinners or your favorite yogurt. See some examples of industries where BOPET is used:

Food & beverage 

Electrical & electronics

Pharmaceuticals

Personal care products

Cosmetics 

BOPE

Biaxially-oriented polyethylene is one of the most common polymer films used in flexible packaging. Some of the biggest benefits of BOPET packages are that they are relatively low cost, have a great heat-seal strength, an excellent moisture barrier, and are durable. BOPE is a great solution for many different types of products, including:

Shopping bags

Pharmaceutical packages

Spices

Liquids

Pesticides

Laundry detergents

Select one of these designs in either high gloss or transparent styles.

LLDPE

Linear low-density polyethylene, or LLDPE, is one of the strongest and most flexible plastic films due to being a blended form of LDPE. Say goodbye to puncturing or tearing, thanks to LLDPE’s high tensile design. On top of being such a durable material, LLDPE maintains the flavor and quality of the contents within each package, prolonging shelf life. 

Since it’s such a versatile material blend, it can also be used in extrusion coating applications to provide an extra layer of protection. Some examples are as follows:

Pond liners

Carpet backing

Paper and paperboard packaging

Pipes

Flexible tubing

Stretch wrap

LDPE

While low-density polythene (LDPE) is the most common type of plastic polymer used, it does lack the strength of LLDPE. Nevertheless, you can find this polymer used in items worldwide from bread bags to coffee lids. 

LDPE can even be recycled, making it a great choice for the eco-conscious shopper. Do you want some ideas of how to use LDPE? Check out examples below:

Six-pack can rings

fresh produce bags

Dry cleaning bags

Garbage bags

The coating on disposable drink cups

Newspaper bags

HDPE

This high-density polyethylene film is revered for its exceptional strength and clarity, making it a favorite in the food industry. If you need a product vacuum-sealed, HDPE is the number one choice to help preserve your food’s flavor and nutritional integrity. See some other products that can benefit from HDPE films:

Recycling bins

Toys

Chemical containers

Haircare products

Food industry

This high-quality and UV-resistant polymer provides a stiffer design option for many products.

 

Foil Packaging

Foil packages are typically used by food, medical, and pharmaceutical industries due to their protective solid barrier. This material keeps food fresh, blocks harmful contaminants, and prolongs shelf life. Foil can also be recycled, which is great for companies seeking sustainable packaging solutions.

Additional Flexible Packaging Film Types

While plastic polymer is widely used, there is an additional film type that is worth noting. Learn more about how laminated film protects package designs for various companies below:

Laminates

If you’re interested in a more intricate flexible packaging solution, consider laminates. These multi-layered structures incorporate polymer films and paper to an aluminum or metalized film. Adding this multi-layered protection ensures that food stays fresher and no external odors make their way into products. This is due to aluminum’s ability to reflect heat and act as a barrier to external gases and moisture. 

Laminate flexible packaging can be found all over, such as:

Pharmaceutical industry

Flavored beverages

Sauces

Ready-to-eat snacks

Freezer-to-microwave

Some medical products

Find Your Perfect Flexible Packaging Film From The Packaging Lab!

We are constantly searching for the latest in innovative packaging solutions for our customers. So, whether you’re looking for sachets, pre-printed vacuum pouches, or anything in-between, our team is ready to help you find the perfect fit for your product.  

Select our custom-printed films with no required minimum quantity.

The Packaging Lab is proud to offer custom-designed flexible packaging solutions with little turnaround time so that you don’t have to worry about downtime in-between rebranding products.  If you’re ready to upgrade to flexible packaging films, contact us today to get started!

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