At ICPG, we work with food brands across categories, and one thing is clear: barrier needs vary dramatically depending on what you’re packaging. Let’s break it down.
Main concern: Oxygen sensitivity.
Dairy products spoil quickly in the presence of oxygen, which accelerates microbial growth and off-flavors. Therefore, packaging designed for low oxygen transmission rate (OTR) is essential. For example, multi-layer coextruded polypropylene (PP) with EVOH barrier structures can significantly extend shelf life of various refrigerated products. In most cases, the filling process and refrigeration provide adequate shelf life protection, however in the case of more sensitive products, the barrier plays a key role in preventing spoilage and extending shelf life.
Best approach: Focus on the oxygen barrier, while ensuring moisture doesn’t cause condensation inside the package.
Main concern: Both oxygen and moisture, depending on formulation.
Acidic condiments like ketchup are relatively shelf-stable but still benefit from protection against oxygen to preserve color and flavor. Oil-based dressings, meanwhile, are prone to oxidation.
Best approach: Materials with balanced barrier properties (like EVOH in multilayer structures) help maintain product integrity over months on the shelf.
Main concern: Moisture sensitivity.
Crispy snacks lose their crunch fast when exposed to humidity. Here, low MVTR is more critical than oxygen. Polypropylene is a popular choice thanks to its excellent moisture barrier properties, which can be combined with EVOH for applications utilizing modified atmosphere processing (M.A.P) that keeps the product fresh while extending shelf life. .
Best approach: Prioritize moisture protection, while ensuring packaging still supports easy sealing and machinability.
Main concern: Controlled oxygen management.
Unlike dairy or condiments, produce often needs a controlled level of oxygen and moisture transfer to prevent spoilage from anaerobic bacteria. Modified atmosphere packaging (MAP) films are tailored with specific OTR/MVTR rates to maintain freshness.
Best approach: Use materials that allow “just enough” oxygen transfer — too high or too low can both shorten shelf life.
Main concern: Extreme oxygen and moisture control.
Products like shelf-stable dairy alternatives, or sauces in thermoformed trays, require very low OTR and MVTR to endure long distribution chains. Multilayer structures with high-barrier resins (EVOH, nylon, etc.) are often necessary to adequately protect the products and in many cases provide 12 to 14 months of OTR/MVTR shelf-life protection.
Best approach: Select structures designed for long-term barrier performance, heat resistance, and protection against both moisture and oxygen.
Understanding oxygen transmission rate (OTR) and moisture vapor transmission rate (MVTR) by category helps prevent over-engineering or under-protecting your product. For instance:
That’s why working with packaging experts matters. At ICPG, we help match your product’s needs with the right material — whether that’s a simple mono-layer PP for moisture protection, or a multilayer structure with EVOH for long-term oxygen control.
Looking for packaging that delivers the right balance of protection and performance? Reach out to our team to discuss your barrier packaging needs.