How to Choose the Right Food Packaging Materials (9 Steps)

September 15

Food packaging materials determine whether your products stay fresh or spoil.

Choosing the wrong food packaging wastes thousands in damaged inventory. The right choices extend shelf life and build customer loyalty.

This guide shows nine proven steps for choosing the best food packaging. You'll discover materials that keep food fresh longer and win repeat customers.

Key Takeaways

• Select materials that meet FDA standards and keep food fresh
• Match your packaging design to your brand and target customers
• Use sustainable materials without losing product protection
• Partner with packaging experts to avoid costly mistakes

What Is Food Packaging and Why It Matters

Food packaging is the process of enclosing food products in protective containers. The packaging prevents contamination, extends shelf life, and provides product information.

Food packaging serves three main functions for your business:

• ➤Primary packaging: Touches your food products (bottles, bags, pouches, trays)
• ➤Secondary packaging: Groups products together (cardboard boxes, shrink wrap)
• ➤Tertiary packaging: Protects during shipping (pallets, crates)

Each level works together to protect your investment and reputation. Poor packaging at any level costs money through damaged products and lost customers.

Almost 7 in 10 consumers judge a brand's food quality by the packaging. Proper packaging builds trust, protects your product, and drives repeat sales. (Source: Ipsos US Packaging Survey)

How to Choose the Best Food Packaging Materials

Follow these nine steps to choose the right packaging for your products and avoid expensive mistakes. Each step builds on the previous one to create a complete packaging strategy.

Step 1: Define Your Food Product's Packaging Needs

Understand your specific product requirements before exploring material options. Defining your needs upfront prevents wasted money on the wrong materials.

Assess your product type:

• Identify whether your product is hot, cold, dry, moist, or frozen
• Match packaging materials to your product's specific temperature and moisture needs

Evaluate shelf life and storage conditions:

• Consider how your product travels from production to customer storage
• Account for shipping stress, warehouse stacking, and retail display conditions

Define your packaging goals:

• Determine priorities beyond basic protection (freshness, visibility, branding, sustainability)
• Balance all requirements to guide your material selection process

Packaging Needs Assessment:

• What temperature conditions will your product face during shipping and storage?
• How long must the product stay fresh from production to consumption?
• What kind of protection does your product need (moisture, oxygen, light, impact)?
• Where and how will customers store and use your product?
• What regulatory requirements must your packaging meet?

• ➤Aripack offers trays, pouches, rigids, and bags for every food product and storage need.

Step 2: Use Food-Safe and Certified Packaging Materials

Food-grade materials protect your customers and prevent regulatory violations. Using the wrong materials causes contamination, product recalls, and lawsuits.

Use food-grade certified materials:

• Pick materials with FDA, ISO 22000, or BRC approval for food contact
• Check that safety certifications match your specific food type

Avoid reactive or unsafe materials:

• Choose BPA-free materials that won't leak chemicals into food
• Test new materials with small batches before full production

Choose trusted materials from experts:

• Work with suppliers who provide FDA certificates and lot numbers for traceability
• Pick packaging manufacturers who supply major brands as proof of quality standards

Food Safety Certification Guide:

• FDA: Required for all food packaging sold in the United States
• ISO 22000: Global food safety standard accepted worldwide
• BRC: Required by major retailers and grocery chains
• GMP: Ensures consistent quality and safety during manufacturing

• ➤Aripack uses only FDA-approved materials for all food packaging. Get your food-safe packaging quote today.

Step 3: Choose Materials That Protect and Preserve Food

Wrong packaging materials cost you money through damaged and spoiled products. Match your material choice to your food's protection needs.

Ensure product durability in transit:

• Choose impact-resistant materials like PET trays for shipping protection
• Pick packaging that resists crushing when stacked in warehouses

Protect against moisture, oxygen, and light:

• Use barrier films like EVOH or foil for foods that spoil fast
• Choose laminated films for coffee and snacks to keep them fresh longer

Choose temperature-appropriate packaging:

• Pick heat-resistant containers for microwaved foods and hot liquids
• Choose freeze-safe materials that handle cold storage without cracking

Protection Level Examples:

• High barrier protection: Frozen dinners and coffee bags prevent spoilage for months
• Medium barrier protection: Snack foods and dry goods stay fresh for weeks
• Low barrier protection: Baked goods and short-shelf-life items protect for days

• ➤Aripack manufactures specialized trays and containers for both hot and cold food.

Step 4: Match Packaging Design to Your Brand Identity

Packaging design builds customer recognition and drives sales through visual appeal. 72% of consumers say food packaging design influences purchase decisions and perceived quality.

Choose materials for product visibility:

• Use transparent materials like PET when your food has appealing colors or textures
• Select windowed polypropylene films to highlight specific ingredients

Choose materials for graphics quality:

• Choose smooth films like BOPP for detailed photography and fine text
• Pick laminated films for complex graphics that need many ink colors

Choose materials for brand positioning:

• Use rigid containers to create a premium feel that customers can touch
• Select matte finishes on plastic containers to reduce fingerprints and glare

Material Types Explained:

• PET: Clear plastic used for bottles and containers
• Polypropylene: Flexible plastic material that resists heat and chemicals
• BOPP: Biaxially oriented polypropylene film with excellent print quality
• Laminated films: Thin plastic sheets bonded together to create stronger protection
• Rigid containers: Hard plastic packaging that maintains its shape
• Matte finishes: Non-glossy surface treatment that reduces light reflection

• ➤Aripack provides custom printing and design services for all packaging materials. Get expert design consultation, including IML, direct printing, and graphics development.

Step 5: Select Eco-Friendly and Sustainable Packaging Options

50% of consumers are willing to pay more for sustainable food packaging materials. They meet growing consumer demand for environmentally responsible products.

Choose recyclable or compostable materials

• Use compostable materials like PLA for cups and containers that break down naturally
• Choose post-consumer recycled (PCR) plastics like PET and PP that turn waste into new food containers

Reduce packaging waste and footprint

• Apply lightweighting to use less material while keeping products safe during shipping
• Use smaller packages that remove extra layers while still protecting your product

Balance sustainability with performance

• Pick eco-materials like paper laminates that block moisture and oxygen to keep food fresh longer
• Consider Aripack's NEO Plastics that help traditional plastic break down safely in landfills

Sustainable Material Guide:

• PLA (Compostable): Plant-based plastic for cups and containers
• PCR Plastics (Recyclable): Recycled plastic turned into new containers
• Paper Laminates (Recyclable): Paper-coated bags and pouches
• NEO Plastics (Landfill-safe): Plastic with added ingredients that break down in landfills

• ➤Ready to reduce your environmental impact? Explore Aripack's sustainable packaging options.

Step 6: Balance Cost with Functionality

The right packaging materials protect your profits and product quality. Cheap materials create expensive problems through spoilage and complaints.

Weigh material cost vs. product price point

• Choose rigid PET containers for premium artisan foods that need shelf presence
• Choose cost-effective PE films for high-volume products where every penny counts

Include the total cost of ownership

• Calculate 15-30% product loss from poor barrier films during shipping and storage
• Factor in extra worker time and customer returns from damaged packages

Explore stock vs. custom packaging solutions

• Use Aripack's stock packaging to launch products with 50% lower setup costs
• Use custom designs to help premium brands earn 20-40% higher profit margins

Cost vs. Value Guide:

• Stock Solutions: Fast delivery, lower costs, small order sizes
• Custom Solutions: Higher prices, unique designs, brand recognition
• Poor Packaging Costs: Product waste, damaged goods, unhappy customers
• Smart Packaging Saves: Less waste, fewer returns, repeat customers

• ➤Need help calculating your packaging ROI? Contact Aripack for data-driven cost analysis.

Step 7: Improve Efficiency with Practical Packaging Formats

Choose food packaging to save time, reduce waste, and lower labor costs. Efficient formats cut downtime during production and reduce shipping space.

Use packaging that stacks, seals, and stores well

• Choose rigid containers with flat bottoms that stack safely during shipping and storage
• Use materials like PET or HDPE that hold shape under pressure and resist leaks

Match packaging to your equipment

• Pick containers that fit your filling machines to avoid production slowdowns and jams
• Use heat-sealable films like BOPP or CPP that work with most standard sealing machines

Simplify logistics and fulfillment

• Choose gusseted bags that ship flat and expand on the shelf to save space
• Use tear-notch or resealable designs to speed up order packing and improve user experience.

Packaging Material Quick Guide:

• PET: A lightweight plastic used for bottles, trays, and clamshells
• HDPE: A dense plastic used for jugs, tubs, and food-safe containers
• BOPP film: A glossy film used in snack food and bakery packaging
• CPP film: A cast film used for lids, pouches, and flexible food wraps
• Gusseted bags: A flexible bag with side or bottom folds that expand to hold more product

• ➤Save time and cut costs with the right packaging format. Talk to Aripack to find the best fit for your product.

Step 8: Adopt Innovative and Future-Ready Packaging Trends

Modern packaging features connect your brand with customers and improve product performance. Use these trending packaging options to give your products a competitive edge.

Add innovative or interactive features

• Add QR codes that link customers to recipes, brand stories, or loyalty programs
• Use freshness indicators that show product quality and build customer trust

Upgrade to next-gen materials

• Try microperforated films like Aripack's KrispPak™ to keep bread fresh
• Choose barrier films with aroma protection that lock in flavors and scents

Consider reusable or hybrid formats

• Use refillable containers for items like spices, coffee, or baking ingredients.
• Create meal kits with separate compartments for sauces, proteins, or toppings.

Innovation Guide:

• QR Codes: Add digital features that connect packaging to mobile experiences
• Freshness Indicators: Use visual cues to show shelf life or product condition
• Microperforations: Improve airflow in packaging for baked or crisp products
• KrispPak™: Aripack-exclusive film designed to extend freshness in bread and baked goods
• Reusable Designs: Containers customers can use again for different purposes

• ➤Also Read: Types of Packaging: Which Is Right for Your Business?

Step 9: Consult a Packaging Expert to Make the Right Choice

Wrong packaging choices can cost thousands in lost products and unhappy customers. Aripack helps you pick the best materials for food and beverage products the first time.

Get personalized recommendations for your product

• Work with experts who understand your product needs, brand goals, and target customers
• Get advice on shelf life, shipping safety, and cost savings for your business

Save time, reduce risk, and scale faster

• Prevent safety issues, sourcing problems, and supply chain delays with expert guidance
• Get help designing packaging that grows with your business and meets future needs

• ➤Ready to make the right packaging choice? Request your custom quote from Aripack's packaging specialists today.

Types of Food Packaging Materials Compared

Each product packaging material offers different benefits. Choose the right material based on your product needs and customer preferences.

1. Plastic Food Packaging Materials

Plastic packaging materials are lightweight, flexible, and cost-effective for most food products. Food-grade plastic offers good barrier protection and works well with automated packaging equipment.

• Polyethylene (PE): Used in plastic bags, stretch wrap, and dairy containers. Includes LDPE and HDPE types
• Polyethylene Terephthalate (PET): Used for water bottles, salad containers, and microwaveable trays
• Polyvinyl Chloride (PVC): Found in cling film, blister packs, and meat packaging
• Polypropylene (PP): Common in yogurt cups, takeout containers, and caps
• Polystyrene (PS/EPS): Used for foam trays, disposable cups, and clamshells

2. Glass Food Packaging Materials

Glass packaging provides excellent barrier protection and gives products a premium appearance. It works best for high-value products that need a long shelf life.

• Glass containers work best for liquid products like sauces and beverages
• Airtight seals keep products fresh for months without spoilage
• Heavier weight increases shipping costs compared to lighter plastic materials

3. Metal Food Packaging Materials

Metal packaging offers superior barrier protection and extends shelf life. It works well for canned goods and products that need long-term storage.

• Tinplate: Used in cans for vegetables, soups, and meats
• Aluminum: Used for beverage cans, trays, foil wraps, and ready-meal containers

4. Paper Food Packaging Materials

Paper packaging materials are environmentally friendly and work well for dry products. They offer good printability for branding, but need coatings for wet products.

• Corrugated Cardboard: Used for shipping boxes and bulk packaging
• Paperboard: Used for cereal boxes, frozen food cartons, and snack boxes
• Coated Paperboard: Used in juice and milk cartons with plastic or foil lining

5. Flexible Food Packaging Materials

Flexible packaging saves space and reduces shipping costs for many products. It offers good barrier options and works well for snacks and convenience foods.

• Plastic Laminates: Found in snack bags, stand-up pouches, and sandwich wraps
• Shrink Film: Used to wrap products together with heat-sealed plastic
• Forming and Non-Forming: Vacuum-sealed film molded to product trays
• Foil Laminates: Used for coffee bags, candy wrappers, and aroma-sealing packs

6. Sustainable Food Packaging Materials

Sustainable and recycled materials meet environmental goals without sacrificing product protection. They appeal to eco-conscious customers and reduce environmental impact.

• Molded Pulp/Fiber: Made from recycled paper for egg cartons and tray inserts
• Compostable Plastics (PLA): Made from corn starch for cutlery, cups, and bags
• Paper Laminates: Replace plastic layers with recyclable paper options

Not sure which food or beverage packaging is best for your product? Talk to Aripack for personalized guidance.

Why Partner with Aripack for Your Food Packaging Needs

• ➤Food brands choose Aripack for reliable packaging that works. We partner with leading companies like Quaker, Lesser Evil, and Godiva.
• ➤Our packaging materials meet the highest food safety standards and global certifications. Your products stay fresh, your customers stay happy, and your business grows faster.

Get Your Packaging Quote Today