Food safe packaging materials are materials that are safe to touch food under their intended conditions of use. They also protect food from oxygen, moisture, light, and contamination. In the US, the Food and Drug Administration (FDA) regulates these food-contact substances under Title 21 of the Code of Federal Regulations (21 CFR).
The most common food packaging materials are plastic films, glass, metal, and paper and cardboard. There are a ton of options out there, and custom food packaging can get nuanced very quickly. Flexible plastic films are a popular choice because they’re light, printable, and built in layers for barrier protection.
In this guide, you’ll learn what makes a material food safe and how the main food packaging types compare. You’ll also see which of six flexible formats fits your product, how to choose a material, and where sustainable food packaging is heading.
What Makes Packaging Materials Food Safe?
Food-safe packaging materials do their job without becoming part of the food. That comes down to four things: compliance, barrier, seal integrity, and the inks and adhesives inside the structure.
- Food-contact compliance: Under 21 CFR 174.5, food-contact components must be of a purity suitable for their intended use, and the FDA assesses migration into food for safety.
- Barrier protection: A barrier is a layer that blocks oxygen, moisture, light, or aroma loss. It keeps food fresh and slows spoilage.
- Seal integrity: A strong, consistent heat seal keeps out air, moisture, and contaminants from filling through final use.
- Food-contact-appropriate inks and adhesives: Inks and laminating adhesives must suit food packaging. Inks are typically buried between layers, away from the food.
“Intended use conditions” means the real-world situation your package faces: the type of food, the temperature, and how long it’s stored. A film that’s safe for dry granola at room temperature may not be the right choice for an oily or acidic product. That’s why compliance always depends on the specific food and how it’s packed, stored, and used.
Suppliers often describe food safe packaging materials as “food grade.” That term is common shorthand for food-contact suitability. Always confirm that the full structure fits your specific product.
The same thinking applies to recycled plastic. Post-consumer recycled (PCR) content is plastic recovered from used consumer packaging, and manufacturers can ask the FDA to review a recycling process for food-contact use. That review is voluntary and case by case, not an approval. We offer PCR packaging options, so ask us which structure fits your product.
Common Food-Safe Plastics in Flexible Packaging
Most flexible food packaging materials are laminates. A laminate bonds two or more films together so each layer can do a different job. These resins are the food safe packaging materials you’ll see most often:
- PET (polyethylene terephthalate): Often the outer layer. It adds stiffness, heat resistance, and a clear, printable surface.
- PE (polyethylene): Usually the inner sealant layer that touches the food. It creates strong heat seals and resists moisture.
- Nylon (polyamide, or PA): Adds toughness and puncture resistance. It’s useful for sharp or heavy products like jerky and nuts.
- Foil and metallized films: Aluminum foil or a thin metal coating on film. Both give a high barrier against oxygen, moisture, and light.
Mixed-material laminates offer strong protection, but they’re generally harder to recycle. Our recyclable pouches use a PE-based structure with high-barrier protection, and they’re store drop-off qualified. On finished packaging, the resin identification code (ASTM D7611) identifies the plastic resin type; it isn’t a recyclability claim on its own.
What Are the Different Types of Food Packaging Materials?
Food packaging materials fall into four main families. Any of them can be food safe when the structure matches the product. Each one balances protection, weight, cost, and end-of-life options differently.
Plastic
Plastic is widely used for its versatility and cost-effectiveness, in formats that range from bottles to bags. Its pros include durability and light weight. Environmental concerns used to be the main con, but advances in recyclable and PCR plastics now give brands more options.
Glass
Glass is often used for liquids and perishable goods, and it’s widely recyclable. Its pros are reusability and a strong barrier. The cons are that it’s heavier and more fragile than other materials.
Metal
Metal is common for canned goods because it’s robust and offers excellent barrier properties. Food-contact coatings on metal containers are regulated under 21 CFR 175.300. Its pros include long shelf life, while cons include higher weight and susceptibility to corrosion.
Paper and Cardboard
Paper and cardboard are ideal for dry goods and takeout food. They’re lightweight, renewable, and widely recyclable when clean and dry. The tradeoff is limited protection against moisture, grease, and pests unless they’re combined with other materials.
Here’s how these food packaging types compare side by side:
| Material | Barrier | Weight | Recyclability | Best Use |
|---|---|---|---|---|
| Laminated plastic film | High; layers can block oxygen, moisture, and light | Very light | Generally hard to recycle when layers mix materials | Coffee, snacks, jerky, powders |
| Mono-material PE film | Moderate to high, depending on structure | Very light | Recyclable through store drop-off where accepted | Snacks, granola, dry goods |
| Glass | Very high | Heavy | Widely recyclable and reusable | Sauces, pickles, beverages |
| Metal | Very high | Moderate to heavy | Highly recyclable | Canned goods, beverages |
| Paper and cardboard | Low without coatings or liners | Light | Widely recyclable when clean and dry | Dry goods, takeout, secondary packaging |
Flexible vs. Rigid Packaging for Food Products
Rigid packaging holds its shape, like boxes, bottles, jars, and cans. Flexible packaging, like pouches, bags, and films, conforms to what’s inside. We’re on Team Flexible with this one, though rigid packaging works for certain products.
In the long run, it’s worth asking whether rigid packaging is good for the environment, and also, what are you selling? A flexible stand-up pouch offers a better option for shelf attention if you’re selling granola or your grandma’s signature blend of spicy nuts.
And with competition so intense for every dollar, stores will take you off the shelves if your packaging doesn’t sell within a short timeframe. Here’s where flexible packaging pulls ahead:
- Lighter shipping: According to the Flexible Packaging Association, flexible packaging is lightweight and requires less energy to transport.
- More shelf impact: Printable surfaces give your brand more room to stand out and sell quickly.
- Less material: Flexible packaging is often lighter and requires fewer resources than rigid alternatives.
Think about shipping a crate of empty bottles versus a box of empty lay-flat bags. The truck space alone is the game-changer for a new business that’s counting its pennies.
Types of Flexible Packaging for Food
In the simplest terms, the food packaging industry is divided into two types: flexible and rigid packaging. Flexible packaging, which our focus leans toward, offers several advantages. Glass and aluminum are excellent choices for products like beer and pickles, but they may not be the best fit for every food item.
Flexible packaging materials also support the sustainability goals that more shoppers look for, because they’re often lighter and use fewer resources. Below, we review six flexible formats to consider for your custom food packaging.
1. Flexible Pouches
Flexible pouches are a popular choice in food packaging, and FPA members report steady industry growth for flexible packaging overall. Customers love them because they look great on the shelf, are durable, and take up much less space than rigid options.
Stand-up pouches are lightweight, which can reduce shipping weight. They can also be customized in many ways, and whatever you dream up can be printed on the pouch.
Stand-up pouches can also include valves that keep oxygen from seeping into the bag and spoiling the product. For a product like coffee or granola, this is a significant win.
When thinking about what’s best for your company, consider the values you champion. If you’re asking the market to trust your brand as a leader in your space, is it based on sustainability or ease of use? Are you working toward being in stores across the country, or are you cool with small batches at the farmer’s market?
2. Roll Stock
Roll stock is one of those things that just makes sense. It’s fast, efficient, affordable, and quick to customize. Because it creates little waste, it also keeps your operational costs low.
Roll stock is printed film on a roll that your equipment forms, fills, and seals on your production line. For vacuum packaging, it uses two rolls of flat film. The bottom layer is a forming film that shapes the package’s base, and the other layer seals it.
3. Mylar Bags
Mylar is the way to go if you need packaging that’ll make the long haul. Mylar, a strong polyester (PET) film, is popular thanks to its high tensile strength, flexibility, and isolating barrier properties.
Mylar is a brand name for polyester (BOPET) film, which is often laminated into high-barrier bags. Because they’re flexible, they conform to the food inside and protect it. Their barrier helps you control the oxygen, light, and humidity that can creep in and degrade food.
4. Lay-Flat Pouches
A lay-flat pouch may be an attractive option if you want something more like a pillow than a package that stands up on a shelf.
Lay-flat pouches offer the same barrier protection as stand-up pouches, but they lie flat instead of standing up. They work well for single servings, snacks, and products displayed on pegs or in bins.
5. Sachet Packaging
Sachets are small, single-use packets for quick one-off samples or on-the-go use. If you’re selling a vitamin powder or a sample of your energy drink powder, they can be a practical tool for promotion. A sachet helps people get to know your brand on a sample basis.
6. Flat Bottom Pouches
Combining the benefits of a stand-up pouch and a traditional bag, flat bottom pouches offer stability and an attractive shelf presence. Their flat base and side gussets (expandable folds) give them a box-like shape. They’re ideal for premium products and can accommodate a variety of closures.
Each of these flexible packaging types offers unique benefits for different needs in the food industry. Your choice depends on product requirements, consumer convenience, and brand positioning. Here’s a quick recap:
- Stand-up pouches: Best for retail shelf presence and products like coffee or granola that benefit from valves.
- Roll stock: Best for automated production lines that need fast, affordable, low-waste packaging.
- Mylar bags: Best for long-term storage and products sensitive to oxygen, light, and humidity.
- Lay-flat pouches: Best for single servings, snacks, and peg or bin displays.
- Sachets: Best for samples, promotions, and on-the-go servings.
- Flat bottom pouches: Best for premium products that need a stable, box-like shelf presence.
How to Choose the Right Food Packaging Material
Choosing food safe packaging materials starts with your product, not the package. Work through these criteria before you request a quote:
- Product type: Note whether your food is dry, oily, acidic, sharp, or powdery. Each affects the sealant layer and barrier you need.
- Shelf life: Decide how long the product must stay fresh. Longer shelf life usually calls for higher barrier, such as foil or metallized film.
- Barrier needs: Identify what your food is most sensitive to: oxygen, moisture, light, or aroma loss.
- Fill method: Match the format to your process. Hand-filled pouches suit small batches, while roll stock fits automated form-fill-seal lines.
- Shelf presence: Think about where the product sells. Stand-up and flat bottom pouches face shoppers, while lay-flat pouches suit pegs and bins.
- Sustainability goals: Decide which claims matter to your customers. We offer recyclable (store drop-off qualified), PCR, and circular packaging options.
- Budget: Weigh unit cost, shipping, and inventory. Ordering only what you need reduces excess stock and waste.
Before full production, test your packed product. Fill and seal sample pouches, then check for leaks, odor transfer, and freshness over time. Catching an issue at this stage costs far less than a recall or a reprint.
What Is the Future for Food Packaging Materials?
The future of food packaging is heading toward sustainability and innovation. Key trends include:
Sustainable Materials
With growing environmental awareness, more brands are choosing sustainable packaging such as recyclable films and packaging made with PCR content. Circular packaging, made from post-consumer recycled material and also recyclable, is gaining ground as well.
Smart Packaging
Brands are integrating technology like QR codes and sensors to track freshness, improve food safety, and enhance the user experience. Through ePacConnect, we offer QR code integration by Scantrust that turns your package into a digital experience.
Minimalism in Design
Packaging is shifting toward simpler, clearer designs that reduce waste and focus on essential elements.
Customization and Personalization
Digital printing makes it easier to create tailored designs for brand differentiation. Our flexible packaging design services can help you build artwork that stands out.
Each of these trends reflects a combination of technological advancement and a response to consumer demand for sustainability and convenience.
Keeping Your Food Packaging Sustainable
Everyday consumers are looking to lessen their carbon footprint, and flexible packaging gives you practical ways to meet them there. At ePac, we’re dedicated to finding new ways to support sustainability.
We’ve worked with our team of experts to develop recyclable packaging that’s store drop-off qualified, plus PCR and circular packaging options. We also keep innovating and improving our circular initiatives.
As of April 2026, seven US states had enacted packaging extended producer responsibility (EPR) laws, so check current requirements in the states where you sell. Customers don’t want to be part of that system. Instead, they choose brands that show a clear commitment to sustainability and a lower carbon footprint.
People read labels and want to know where a material came from and what happens after it’s used. If you’re exploring custom food packaging, we’d love to help you choose food-safe packaging materials that protect your product and wow customers everywhere. Get Pricing to see what your next custom pouch could cost.