Flexible Packaging Structure Selector
Recommendations are general guidance. Final structure depends on your product, filling line and shelf-life target.
Your requirements
Recommendations are general guidance. Final structure depends on your product, filling line and shelf-life target.
How it's calculated
This is a rule-based selector, not a calculator. Each product has a base structure table; your top priority can switch the main pick to a different structure from the same table.
Thickness ranges, barrier levels and transparency are typical values, please confirm with your data. They vary with film grades and suppliers.
Adding a window lowers the barrier level by one step (Very high to High, High to Medium, Medium to Low) and a reminder is shown.
A degassing valve is only recommended for products that release gas after packing, such as roasted coffee.
Food-grade materials available on request. Abbreviations: PET polyester, VMPET metallized PET, AL aluminium foil, PE polyethylene, PA nylon, BOPP oriented polypropylene, VMCPP metallized cast PP, RCPP retort cast PP, EVOH ethylene vinyl alcohol.
How to use
1. Choose your product
Select the product you plan to pack. This sets the base structure options.
2. Set your top priority
Pick the one factor that matters most, such as barrier, transparency or recyclability.
3. Add features and review
Tick extra features. The recommendation updates instantly, with a primary pick and an alternative.
A worked example
Default inputs: Roasted coffee, top priority Maximum barrier, no extra features selected.
- Primary structure: PET12 / AL7 / PE80, typical total thickness 90 to 140 µm.
- Barrier level: Very high. Transparency: Opaque. Recyclability: Multi-material.
- Alternative: PET12 / VMPET12 / PE80, barrier High, typical thickness 80 to 130 µm.
- Adding a window would lower the barrier by one step, so the primary pick would show High.
FAQ
Can I get a fully recyclable pouch with high barrier?
Mono-material PE or PP pouches can be recycled where facilities exist. For more barrier, an EVOH co-extruded layer can be considered, but its barrier is lower than aluminium foil.
What is the difference between VMPET and aluminium foil?
VMPET is PET with a very thin metal coating. Aluminium foil gives a higher barrier. VMPET is usually lighter and more flexible. Please confirm with your own shelf-life data.
Does coffee need a degassing valve?
Freshly roasted coffee releases gas after packing, so a one-way degassing valve is commonly used to prevent pouches from swelling while keeping oxygen out.
How does a window affect protection?
A window lets the product be seen but also lets in light and reduces barrier at that area. This tool lowers the barrier level by one step when a window is selected.
Is the thickness shown the final specification?
No. Ranges are typical values, please confirm with your data. Final thickness depends on pack size, fill weight and your filling line, and is confirmed in your quotation.
Related tools
Have a project in mind?
Send us your product and target structure. Food-grade materials available on request.
Get a Free QuoteResults are estimates for planning purposes. Final specifications and prices are confirmed in your quotation.