Introduction
Package of any product is crucial for its protection against damage or spoilage. In this context of utmost importance are the packaging materials and the methods used for storage and transportation of the products. The traditional packaging methods like tin, glass, jute etc. have given way to flexible packaging, which is a multi-billion industry today. A very broad definition of flexible packaging would be packaging in which the shape can readily be changed. Materials used in flexible packaging are films, foils, papers. Flexible packaging has more advantages compared to any other packaging methods. It is most versatile, materials used are proven safe and effective, it is lightweight, materials usage is optimum, it has superior barrier properties, the processes of packaging are clean and hygienic, it offers convenience. Flexible packaging is widely used for food packaging mainly because there are a variety of food products each having specific requirements. Flexible packaging can cater to each of them effectively. This article gives detailed information on the various forms of flexible packaging and their applications in food and non-food products.
Applications in Pharmaceuticals
Nutraceuticals are an evolving product. You are not really sure in which form they will end up in a few years down the line. They may start as pills and become gels, or may be just encapsulated oils. Flexible packaging can be a solution for all these products because of its ability to change pack configurations without high costs and offer various material structures to suit different product needs.
Public awareness of healthcare and the demand for quality of life have caused recent growth of the nutraceutical, functional food, and natural health product markets. This new field derives from the small pharmaceutical companies, and products are often produced in small batches, have a small market or are in the form of a clinical trial. These nutraceuticals and natural health products often require oxygen-sensitive packaging. This is where flexible packaging can offer the most benefit, because it offers a perfect solution for all batch sizes and provides a high oxygen and moisture barrier to protect sensitive products, which is a necessary requirement for nutraceuticals in order to prevent regulation as food. Soula is high on the potential of flexible packaging in this field.
In recent years, almost all pharmaceuticals industry has adopted flexible packaging in the form of blister packets and strip packs due to their high visibility and ability to promote compliance with product regimens by providing a single dose. Flexible packaging has also been critical in the unit-dose packaging, as it provides the precise level of medication required, is cost-effective, and saves material and energy. The information age has also caused an increase in the demand for pharmaceuticals delivered in the form of transdermal patches and inhalants. Film and foil pouches are the perfect solution for these delivery systems as they provide a barrier to light, oxygen, and moisture, and can deliver the medication in precise doses with high flexibility.
Applications in Cosmetics
The primary importance of packaging material in the pharmaceutical and cosmetics industries is the need for increased shelf-life of the products. With such products having a wide range of sensitive ingredients, including vitamins, essential oils, and herbs, the key requirement in packaging materials is a controlled environment. Flexible packaging offers a far wider range of protection to various products than conventional packaging. The perishable nature of some cosmetics and personal care items, such as fragrance and essential oils, is the main reason for the development of stand-up pouches with integral “pour spouts” and aerosol packaging. Stand-up pouches are made from a laminate of different plastic films, which when printed and the desired pouch shape is formed, then sealed. This type of packaging is very flexible in regard to the specification of the laminate, which can aid in providing the required protection of the product. The laminate can be tailored to provide high moisture barrier properties and the films can be surface printed using high-quality graphics. This version of the pouch is constructed from a polyester film, with a metallized PET film providing the high barrier and an outer layer of clear sealable film.
This will provide print protection on the inside of the pouch and good clarity for the consumer. Another type of stand-up pouch is the retortable version, mainly used for food but is also suitable for some cosmetics and personal care items. This pouch is constructed using three layers of aluminum foil, which provides an extremely high barrier to water vapor and oxygen, ink protection, and near total opacity. The hardest wearing and best looking pouch is made with a PET outer for print, and a metallized PET layer. Flexible packaging can also be manufactured using fewer resources than some traditional packaging, which fits with the current market trend to more sustainable packaging solutions. This can be achieved by source reduction of the packaging, which in flexible terms means constructions using less material layers, thinner films, and less bulky pouch shapes. Stand-up pouches can be designed for minimum material use, with the ability to make a pouch that is much lighter in weight than an equivalent rigid plastic container.
Further to the pouches, flexible packaging also offers a range of bags and sachets, constructed with quality and convenience in mind. The nature of flexible materials allows the manufacturer to produce a variety of bag styles, using form, fill and seal machines with a variety of films and inks to suit the product. Onion and garlic oils can be packaged in a small sachet for single-use application, using the minimum level of packaging to provide the best protection. The single-use concept is also true for wet wipe and face mask sachets, which are convenient to carry in a handbag or travel bag. Stand-up pouches and bags provide excellent space-saving and the ability for simple product dispensing for items like liquid soaps and shampoos. An example is the successful transfer by Proctor and Gamble of the Aussie and Pantene hair care products from rigid bottles to stand-up pouches, which provided very successful results with the return to bottles being unfavorable for the consumer. Compliance to brand owner and consumer desires is the major factor in the success of the pouch.
Other Applications
Changing lifestyles due to increased health awareness and rising income levels are leading to consumers spending more on personal care. The good news for the packaging industry is that products used in personal care generally require higher levels of packaging, to protect and dispense the product. This represents added value for the consumer and thus a stimulus to the market. Thus personal care products are often packed in materials that were originally developed for the food industry, for example, they may be packed in laminates made from aluminium foil or transparent high barrier materials.
Though there will be technology transfer from the food industry, personal care products have their own requirements for packaging, albeit generally less demanding than those of pharmaceuticals. The lower cost sector of personal care products will continue to insist on single material packaging, primarily in the form of polyolefin based materials. For example, individually wrapped wet wipes are best packed in low cost, easy open, peelable pouches made from medium to high density polyethylene or polypropylene.
Foil based laminate structures are more likely to be used for face masks or anti-bacterial and anti-ageing products which tend to have higher perceived values and thus support higher packaging costs. In contrast to food and medicine, there is no regulation specific to packaging of personal care products in the EU. This is not to say that there are no legislative requirements. Indeed the personal care product is an area where companies must ensure their packaging materials comply with general food contact legislation, whilst there may also be requirements pertaining to other product specific legislation coming from the personal care product itself. An example of the latter would be a medicinal product claim wherein the product would have to be treated as a pharmaceutical. Enforcement of legislation in the personal care sector is often less stringent than that in the food and medicine sectors. Nevertheless, the absence of specific legislation allows greater freedom for the personal care product in making packaging choices.
Conclusion
In the pharmaceutical and medical industries, the drive toward use of cost-effective, user-friendly, and tamper-evident packaging will support increased utilization of flexible packaging. The efficacy of flexible packaging in providing a safe, low-cost, and user-friendly alternative to traditional packaging systems has already established strong support in the medical industry. It is not difficult to envision future use of flexible packaging in the medical industry extending beyond the boundaries of products designed for consumers, to the packaging of medical supplies and devices used by healthcare institutions. However, this migration of packaging systems into a regulated industry will present some challenges, in that the U.S. Food and Drug Administration and its foreign counterparts have inherited a traditionalist’s attitude toward packaging as a component of a medical product.
The multiplicity of flexible packaging applications worldwide is a testament to its growth and development as a technologically advanced form of packaging. It has successfully satisfied complex packaging requirements across a wide array of industries, and consideration of a few key factors will facilitate the successful integration of flexible packaging in a wider variety of consumer products. These include a need for increased education of both manufacturers and consumers as to the benefits of flexible packaging, development of improved packaging technology and materials with consideration of industry specific requirements, and a marketing strategy designed to change consumer expectations of packaging.
