Selecting the best barrier layer for packaging depends on several factors. Product type, shelf life, cost, and manufacturing process play important roles. Aluminum foil offers excellent protection against moisture, oxygen, and light. Nylon provides strong mechanical strength and works well for high-temperature products. EVOH delivers superior oxygen barrier properties, ideal for foods that require long shelf life. The global EVOH film market is projected to reach US$ 9.03 billion by 2034, showing strong demand. Efficient manufacturing, such as with lami tube making machine, supports rapid production and reduces material waste. The following table highlights a barrier layer comparison:
| Material | Barrier Properties | Shelf Life Impact | Cost Efficiency | Manufacturing Process |
|---|---|---|---|---|
| Aluminum Foil | Excellent barrier against moisture, oxygen, and light | Maintains food quality and freshness | Lightweight, recyclable | Easy to process |
| Nylon | Good mechanical strength, high barrier performance | Extends shelf life for hot and frozen goods | Moderate | Versatile for food packaging |
| EVOH | Extremely high oxygen barrier properties | Keeps oxygen-sensitive foods fresh longer | Higher costs | Enhances composite materials |
Key Takeaways
- Aluminum foil provides excellent protection against moisture, oxygen, and light, making it ideal for food and pharmaceutical packaging.
- EVOH offers superior oxygen barrier properties, helping to keep food fresh longer, especially in low-humidity environments.
- Nylon is strong and flexible, making it suitable for vacuum sealing and refrigeration applications, but it can absorb moisture over time.
- Choosing the right barrier material depends on factors like product type, shelf life, cost, and the manufacturing process.
- Testing different materials in small batches can help manufacturers find the best packaging solution for their specific needs.
Barrier Layer Comparison
Why Barrier Materials Matter?
Barrier materials play a crucial role in packaging by protecting products from environmental factors. These materials help maintain freshness, prevent spoilage, and extend shelf life. Scientists have found that edible films and coatings can inhibit moisture loss and gas exchange, which keeps food fresh longer. Some coatings also offer antibacterial and antifungal properties, making them effective for food preservation. Apeel’s invisible coating slows down spoilage by controlling water evaporation and oxygen exposure, helping fruits and vegetables stay fresh and reducing food waste. Double-layered PET pouches can extend shelf life from one to eight years under ambient conditions. Multilayer pouches with high-barrier properties are essential for maintaining the stability of sterilized food products.
- Edible films and coatings inhibit moisture loss and gas exchange, extending shelf life.
- Some coatings possess antibacterial and antifungal properties, enhancing food preservation.
- Apeel’s invisible coating slows spoilage by controlling water and oxygen exposure.
- Double-layered PET pouches extend shelf life up to eight years.
- High-barrier multilayer pouches maintain stability for sterilized foods.
High Barrier Materials Overview
Barrier materials protect packaged goods from moisture, oxygen, and light. Recent research highlights several advanced technologies that improve packaging performance. The table below summarizes how different barrier technologies function and their benefits:
| Barrier Technology | Description | Benefits |
|---|---|---|
| Nanolayer Bottle Architecture | Co-extrudes EVOH and polyethylene layers, encapsulated by amorphous polyester | Prevents haze, boosts toughness, maintains low transmission rates |
| Liquid Film Application | Applies thin PVOH or EVOH layers for oxygen protection, heals defects | Achieves aluminum-equivalent shelf life with minimal polymer use |
| Multi-pass Coating | Smooths paper with PVOH, deposits AlOx or SiOx layers | Achieves low oxygen transmission rates, maintains repulpability |
| CO₂-rich Master-pouch MAP | Uses secondary barrier pouch with gas-flushing | Extends shelf life, maintains product freshness |
Barrier materials such as aluminum foil, EVOH, and nylon each offer unique advantages. Aluminum foil for ABL tube remains a top choice for medical packaging due to its effectiveness against water vapor and oxygen. EVOH provides excellent oxygen barrier properties, especially when dry, while nylon offers toughness and resistance to abrasion and oil. Companies now explore non-foil options to address sustainability concerns, but barrier materials continue to be essential for protecting products and extending shelf life.
Aluminum Foil
Properties
Aluminum foil stands out for its excellent barrier properties against moisture, oxygen, and light. Manufacturers often choose high purity grades of aluminum for packaging because these grades offer strong corrosion resistance and chemical stability. The material’s low density and high ductility allow it to form tight seals, which are essential for maintaining product freshness. Aluminum foil composite film enhances these high barrier properties, making it suitable for packaging meat and other sensitive products. The table below summarizes the measured barrier properties:
| Property | Measurement Unit | Description |
|---|---|---|
| Moisture transmission | g/m²/day or g/100 in²/24 hr | Amount of moisture transmitted through the material in 24 hours. |
| Oxygen transmission | cc/m²/day or cc/100 in²/day | Amount of oxygen passing through the material over a specific area in 24 hours. |
| Light barrier | N/A | Aluminum foil provides a barrier to light, protecting contents from UV and visible light. |
Advantages
Aluminum foil delivers excellent barrier properties, which help extend the shelf life of food and meat products. Its excellent gas barrier keeps oxygen and moisture away from packaged goods. The material is lightweight, recyclable, and meets international food safety standards. Aluminum foil composite film offers high barrier properties for both food and pharmaceutical packaging. The strong tensile strength and flexibility of aluminum foil make it ideal for use in laminated tube production and laminated tube making machine. The machine relies on aluminum foil’s formability to create tight seals that protect contents from external contaminants.
Tip: Aluminum foil’s high barrier properties make it a preferred choice for packaging meat, dairy, and ready-to-eat meals.
Limitations
Aluminum foil has some limitations in packaging applications. The surface is relatively soft, which makes it susceptible to abrasion and wear. The production cost of aluminum foil is higher than some plastic alternatives. Aluminum foil is not suitable for microwave heating, which restricts its use in certain food packaging scenarios. The weight of aluminum can increase transportation costs for large shipments. Environmental impact from aluminum production remains a concern, although recycling helps reduce this effect.
| Limitation | Description |
|---|---|
| Relatively High Cost | Production cost is higher than some plastics. |
| Heavy Weight | May increase transportation and handling costs. |
| Susceptible to Wear | Surface is soft and can be damaged by friction. |
| Not Suitable for Microwave Heating | Limits use in some food packaging. |
Applications
Aluminum foil is widely used in food packaging, especially for meat, dairy, and baked goods. Pharmaceutical companies rely on aluminum foil for packaging medications, as it maintains stability and efficacy by blocking moisture, light, and oxygen. Beverage packaging and aluminum foil containers are common in fast food and takeout restaurants. The material’s high barrier properties make it suitable for laminated tube production, where lami tube making machines use aluminum foil composite film to create packaging for toothpaste, creams, and ointments. Aluminum cans also benefit from the excellent barrier properties and durability of aluminum foil.
- Food packaging for meat, dairy, and baked goods
- Pharmaceutical packaging for tablets and capsules
- Beverage packaging and aluminum cans
- Fast food containers and takeout packaging
- Laminated tube production using lami tube making machine
EVOH Barrier Materials
Properties
EVOH stands out in packaging for its unique combination of high oxygen barrier and transparency. Manufacturers value EVOH for its ability to retain food flavor and color, while also providing a glossy, attractive appearance. EVOH coextrusion film technology allows for versatile applications, including thermoformed packaging and laminated tube production. EVOH is recyclable and adapts well to different packaging formats, making it suitable for use with laminated tube making machine. The following table compares oxygen transmission rates of EVOH and other barrier materials:
| Film Type | OTR @ 73°F (23°C), 0% RH (cc/100 in²/24 hr) | OTR @ 73°F (23°C), 0% RH (cc/m²/24 hr) |
|---|---|---|
| EVOH | .005 -.12 | .08 – .19 |
| Biax Nylon-6 | 1.2 – 2.5 | 18.6 – 39 |
| OPET | 2 – 6 | 31 – 93 |
| OPP | 100 – 160 | 1550 – 2500 |
| Cast PP | 150 – 200 | 2300 – 3100 |
| HDPE | 150 – 200 | 2300 – 3100 |
| OPS | 280 – 400 | 4350 – 6200 |
| LDPE | 450 – 500 | 7000 – 8500 |
Advantages
EVOH for PBL tube offers superior high barrier performance against oxygen, which helps preserve the freshness and aroma of packaged goods. Its transparency and high gloss enhance the visual appeal of products. EVOH coextrusion film provides flexibility for manufacturers, allowing integration into laminated tube and laminated tube making machine. EVOH protects oxygen-sensitive products by blocking unwanted odors and maintaining fragrance. The table below highlights the advantages of EVOH compared to aluminum foil and nylon:
| Material | Transparency | Oxygen Barrier Performance |
|---|---|---|
| EVOH | High | Superior |
| Aluminum Foil | Opaque | Moderate |
| Nylon | Moderate | Low |
Note: EVOH coextrusion film is ideal for packaging that requires both high oxygen barrier and visual clarity.
Limitations
EVOH’s barrier properties depend on environmental humidity. EVOH maintains its high oxygen barrier in environments with relative humidity below 20%. When humidity rises above 30%, water molecules interact with EVOH, causing the polymer to swell and increasing oxygen transmission rates. At relative humidity above 60%, the oxygen barrier can decrease significantly, and shelf life may be reduced. EVOH-based packaging may not perform as well in high-moisture environments, which can affect applications such as refrigerated foods. Manufacturers using lami tube making machine must consider humidity control during production.
- EVOH maintains barrier properties at low humidity.
- Oxygen transmission rate increases as humidity rises.
- Shelf life may decrease in high-humidity environments.
Applications
EVOH finds widespread use in flexible packaging due to its high oxygen barrier and versatility. Food and beverage packaging represents a major market, with projected revenue of USD 1.2 billion in 2024. Pharmaceutical packaging also benefits from EVOH’s ability to protect sensitive products. Industrial packaging uses EVOH coextrusion film for chemical and technical goods. Laminated tube line and lami tube making machine rely on EVOH for toothpaste, creams, and cosmetic packaging. EVOH’s recyclability and adaptability make it a preferred choice for modern packaging solutions.
| Application | Market Share/Revenue Projection | Growth Drivers |
|---|---|---|
| Food and Beverage Packaging | USD 1.2 billion in 2024 | Increasing demand for packaged food and beverages |
| Pharmaceutical Packaging | Significant growth expected | Rising demand for blister packs and vials |
| Industrial Packaging | Steady expansion anticipated | Increasing use in chemical and industrial packaging |
Nylon Barrier Materials
Properties
Nylon stands out in packaging for its impressive mechanical strength and flexibility. Manufacturers value nylon for its ability to withstand heavy-duty use while remaining lightweight. The material resists punctures and scratches, which helps protect packaged goods during transport and storage. Nylon also offers a high melting point, making it suitable for heat processes in manufacturing, such as those used in lami tube making machines. Its natural elasticity allows nylon to stretch and return to its original shape, ensuring that laminated tubes and other packaging maintain their integrity.
| Property | Description |
|---|---|
| Tensile Strength | Outstanding tensile strength suitable for heavy-duty applications. |
| Puncture Resistance | High puncture resistance ensuring integrity of packaged goods. |
| Flexibility | Remains flexible and transparent for easy handling and visibility. |
| Heat Resistance | High melting point allows for heat setting processes in manufacturing. |
| Moisture Interaction | Hygroscopic nature allows for moisture absorption and quick drying times. |
Advantages
Nylon provides several advantages for barrier packaging. Its high mechanical strength and excellent flexibility make it ideal for products that require durability and resistance to damage. Nylon’s natural low friction properties help prevent wear and tear during handling. The material’s toughness and elasticity support the production of laminated tubes that must endure repeated squeezing and bending. Nylon also offers a strong oxygen barrier, which helps preserve food quality. Manufacturers often choose nylon for its cost-effectiveness, as it reduces shipping costs due to its lightweight nature and supports energy-efficient production.
Tip: Nylon’s combination of strength, flexibility, and barrier performance makes it a popular choice for vacuum sealing and refrigeration applications.
Limitations
Nylon absorbs moisture from the environment, which can affect its barrier properties over time. The material’s hygroscopic nature means it may swell or change shape when exposed to high humidity. While nylon performs well in many packaging scenarios, it may not provide the highest barrier against oxygen compared to materials like EVOH. However, its mechanical strength and flexibility often outweigh these concerns, especially in applications where durability is critical.
Applications
Nylon barrier materials serve a wide range of packaging needs. Vacuum food bags made from nylon extend shelf life and prevent spoilage, making them common in both households and restaurants. Nylon’s excellent puncture resistance and flexibility make it suitable for packaging greasy foods, meats, fried items, and products with sharp edges. The material performs well in freezing, refrigeration, and room temperature storage. Manufacturers use nylon in the production of laminated tubes with lami tube making machine, ensuring that toothpaste, creams, and other products remain protected and easy to dispense.
| Application Area | Benefit |
|---|---|
| Vacuum Sealing | Extends shelf life and prevents spoilage |
| Refrigeration/Freezing | Maintains flexibility and barrier properties at low temperatures |
| Laminated Tube Production | Supports durable, flexible packaging for personal care and food products |
Comparison of Barrier Materials
Performance
Barrier layer comparison plays a vital role in packaging technology. Manufacturers evaluate barrier performance by measuring oxygen and moisture transmission rates. Aluminum foil demonstrates the highest barrier performance, with oxygen transmission rates (OTR) and moisture vapor transmission rates (MVTR) both at or below 0.0001 cc/m²/day and g/m²/day, respectively. EVOH also provides excellent oxygen barrier properties, with OTR values at or below 0.01 cc/m²/day and MVTR between 10-15 g/m²/day. Nylon, while strong and flexible, shows higher OTR at 30 cc/m²/day and MVTR at 11 g/m²/day.
| Material | OTR (cc/m²/day) | MVTR (g/m²/day) | Applications |
|---|---|---|---|
| EVOH | ≤0.01 | 10-15 | High barrier for oxygen-sensitive products |
| Aluminum Foil | ≤0.0001 | ≤0.0001 | Pharmaceuticals, high-performance packaging |
| Nylon (15um) | 30 | 11 | Flexible packaging, vacuum sealing |
Aluminum foil excels in high barrier materials, especially for products requiring maximum protection against moisture and oxygen. EVOH stands out for its superior oxygen barrier, making it ideal for extending shelf life in food and pharmaceutical packaging. Nylon offers reliable barrier performance for flexible packaging, vacuum sealing, and refrigerated storage. Manufacturers using lami tube making machine often select aluminum foil or EVOH for laminated tube production, ensuring optimal barrier layer comparison and product safety.
Note: High barrier materials like aluminum foil and EVOH help preserve product quality and extend shelf life, especially for oxygen-sensitive goods.
Cost
Cost considerations influence the choice of barrier materials in packaging. Aluminum foil, while delivering outstanding barrier performance, often comes with higher production costs due to its manufacturing process and raw material expenses. EVOH, recognized for its high oxygen barrier, typically costs more than standard plastics but less than aluminum foil. Nylon provides a cost-effective solution for applications where mechanical strength and flexibility are priorities, though its barrier performance does not match that of aluminum foil or EVOH.
| Material | Relative Cost | Cost Efficiency |
|---|---|---|
| Aluminum Foil | High | Best for premium, high barrier needs |
| EVOH | Moderate | Balances performance and cost |
| Nylon | Low | Suitable for cost-sensitive packaging |
Manufacturers using lami tube making machine weigh the cost of each material against the required barrier performance. Laminated tube line benefits from EVOH’s balance of cost and oxygen barrier, while nylon supports affordable packaging for everyday products. Aluminum foil remains the preferred choice for applications demanding the highest level of protection, despite its higher price.
Use Cases
Barrier layer comparison extends to practical applications in food and pharmaceutical packaging. Aluminum foil serves as the gold standard for packaging sensitive medications and foods that require long shelf life. EVOH finds use in extending shelf life for perishable foods and protecting pharmaceuticals from oxygen exposure. Nylon, with its flexibility and mechanical strength, is common in flexible packaging for food and medical devices.
| Material | Use Cases in Food Packaging | Use Cases in Pharmaceutical Packaging |
|---|---|---|
| EVOH | Extending shelf life of perishable foods | Protecting sensitive pharmaceuticals |
| Aluminum Foil | Excellent barrier against moisture, oxygen, and light | Packaging sensitive medications |
| Nylon | Flexible packaging for food | Medical device packaging |
Manufacturers rely on high barrier materials to meet specific packaging needs. Aluminum foil and EVOH are frequently chosen for laminated tube production using lami tube manufacturing machine, ensuring products like toothpaste, creams, and ointments remain safe and fresh. Nylon supports packaging for vacuum-sealed foods and refrigerated items, where durability and flexibility matter most.
Tip: Selecting the right barrier material depends on the product’s shelf life requirements, cost sensitivity, and the desired barrier performance.
Choosing High Barrier Materials
Selection Tips
Selecting the right barrier materials for packaging requires careful evaluation of several factors. Each product has unique needs, and the choice of materials can greatly affect shelf life, safety, and cost. The following criteria help guide the decision-making process:
- Physical Properties: Consider thickness, density, and weight. These influence how well the packaging protects the product.
- Mechanical Properties: Assess strength, flexibility, and resistance to punctures or tears. Strong materials prevent damage during transport.
- Thermal Properties: Check heat resistance and stability. Some materials perform better at high or low temperatures.
- Chemical Properties: Evaluate compatibility with the product. Materials must not react with contents or allow contamination.
- Optical Properties: Decide if transparency or opacity is needed. Some products benefit from visible packaging, while others require light protection.
- Processing Method: Ensure the material suits the chosen manufacturing process, such as lami tube making machines.
- Barrier Properties (OTR & MVTR): Review oxygen and moisture transmission rates. High barrier materials keep products fresh longer.
- Recycling: Choose materials that support sustainability goals. Recyclable options help reduce environmental impact.
- Regulatory Compliance: Confirm that materials meet food safety and pharmaceutical standards.
- Cost: Balance performance with budget. Some high barrier materials may cost more but offer better protection.
Tip: Manufacturers often test different materials in small batches before full-scale production. This approach helps identify the best combination for specific packaging needs.
Manufacturing Considerations
Manufacturers must understand how different barrier materials behave during production. Each material brings unique properties that affect processing, sealing, and final product quality. The table below summarizes key manufacturing considerations for aluminum foil, EVOH, and nylon:
| Material | Key Properties | Role in Packaging |
|---|---|---|
| Nylon | Toughness, low permeability to oxygen, flexible | Protects products, enhances longevity, suitable for composite packaging |
| EVOH | Exceptional barrier against gases, recyclable | Extends shelf life, maintains product freshness, used in multi-layer structures |
| Aluminum Foil | Impermeable to light, moisture, and air | Preserves flavors and nutrients, extends shelf life, compatible with sealing techniques |
When integrating these materials into packaging lines, especially with lami tube making machine, manufacturers should consider the following:
- Nylon provides toughness and flexibility. It works well for vacuum-sealed packages and composite structures. Its low oxygen permeability helps protect sensitive products.
- EVOH offers superior barrier qualities against oxygen. It maintains product freshness and supports sustainability efforts due to its recyclability. Manufacturers often use EVOH in multi-layer packaging to maximize shelf life.
- Aluminum foil acts as a complete barrier to light, moisture, and air. It preserves flavors and nutrients and is compatible with various sealing techniques. Its recyclability adds value for eco-conscious brands.
Note: Proper calibration of lami tube making machine ensures optimal bonding and sealing of these materials. Regular maintenance and quality checks help maintain consistent barrier performance.
Manufacturers should match the properties of each material to the product’s requirements and the chosen production method. By understanding both selection criteria and manufacturing considerations, companies can create packaging that delivers safety, freshness, and efficiency.
Conclusion
Recent studies show that barrier materials like PA/EVOH/PE have minimal impact on flavor, odor, and appearance, making them ideal for sensitive products.
| Barrier Material | Effect on Flavor | Effect on Odor | Effect on Appearance |
|---|---|---|---|
| PE | Significant reduction | Significant reduction | Significant reduction |
| PE/EVOH | Significant reduction | Significant reduction | Moderate reduction |
| PA/PE | Moderate reduction | Moderate reduction | Moderate reduction |
| PA/EVOH/PE | Minimal effect | Minimal effect | Minimal effect |
Manufacturers recommend balancing flexibility, barrier efficiency, and compatibility with product contents. They often select phenolic for strength and heat resistance, and epoxy for moisture protection. Consulting suppliers or lami tube making machine experts helps ensure the best packaging solution.
FAQ
What Is the Role of Oxygen Barrier Coatings in Packaging?
Oxygen barrier coatings protect products from oxygen exposure. They help maintain freshness and extend shelf life. Manufacturers use these coatings to improve the oxygen barrier property of packaging materials. This technology supports food, pharmaceutical, and cosmetic industries.
How Do Barrier Materials Affect Shelf Life?
Barrier materials block moisture, oxygen, and light. They prevent spoilage and keep products safe. Companies select packaging with strong oxygen barrier property to extend shelf life. The right barrier ensures food and medicine remain fresh for longer periods.
Tip: Choosing packaging with high oxygen barrier coatings helps preserve flavor and quality.
Why Is Oxygen Barrier Property Important for Food Packaging?
Oxygen barrier property keeps food from spoiling quickly. It stops oxygen from entering the package. This barrier protects color, taste, and nutrients. Food manufacturers rely on packaging with strong oxygen barrier coatings to deliver safe products to consumers.
Which Packaging Materials Offer the Best Oxygen Barrier?
Aluminum foil, EVOH, and nylon provide excellent oxygen barrier property. EVOH stands out for its high oxygen barrier coatings. Aluminum foil blocks both oxygen and moisture. Nylon offers flexibility and moderate barrier performance. Each material suits different packaging needs.
| Material | Oxygen Barrier Property | Typical Use |
|---|---|---|
| Aluminum Foil | Excellent | Food, pharma |
| EVOH | Superior | Flexible packaging |
| Nylon | Good | Vacuum sealing |
How Do Manufacturers Test Barrier Performance in Packaging?
Manufacturers measure oxygen transmission rates and moisture vapor transmission rates. They use specialized equipment to test barrier effectiveness. These tests ensure packaging meets safety standards and provides reliable oxygen barrier property for products.