Food packaging film: selection guide

The most common film structures for vacuum and MAP

PA/PE (polyamide/polyethylene) is the most widespread structure for vacuum packaging. PA ensures mechanical resistance and oxygen barrier, PE is the sealing layer. In coextrusion the two resins form a flexible film with good barrier. Typical thicknesses: 60-100 µm for general use, 80-120 µm for products with sharp surfaces.

EVOH (ethylene-vinyl alcohol copolymer) adds an extreme oxygen barrier layer (OTR < 1 cm³/m²·24h·atm at 0% relative humidity). Used in PA/EVOH/PE or PP/EVOH/PP structures for products requiring shelf life > 6-12 months or high oxidation sensitivity (fatty cheeses, meat-based products).

• Bioriented PA/PE: vacuum and MAP standard, OTR 20-40 cm³/m²·24h
• PA/EVOH/PE: high barrier, OTR < 2 cm³/m²·24h, long shelf life
• PP/PE: economical, transparent, OTR 100-300 cm³/m²·24h
• PET/PE: rigid, for tray thermoforming
• CPET: oven-resistant, for cook-in ready meals

OTR and WVTR: the key parameters for selection

OTR (Oxygen Transmission Rate) measures how many cm³ of O₂ pass through 1 m² of film in 24 hours at standard temperature. The lower, the better the barrier. For oxidation-sensitive products (meat, aged cheeses) films with OTR < 5-10 cm³/m²·24h are needed. For stable products like dry pasta, OTR can be 50-100 cm³/m²·24h.

WVTR (Water Vapor Transmission Rate) measures water vapour permeability. Critical for high-moisture products that may dehydrate (ham, mozzarella) or dry products that must stay crunchy (snacks). Too-high WVTR dehydrates the product or lets moisture in from outside.

• OTR < 1 cm³/m²·24h: fatty cheeses, oxidisable products, shelf life > 6 months
• OTR 2-10 cm³/m²·24h: meat, cured meats, fish, 30-90 day shelf life
• OTR 10-50 cm³/m²·24h: fresh pasta, short-term refrigerated products
• WVTR < 2 g/m²·24h: dry products, snacks, crunchiness
• WVTR 3-10 g/m²·24h: fresh moist products, cheeses, meat

Film thickness: when it really matters

Film thickness influences mechanical resistance, barrier properties and cost. Thicker film does not necessarily mean better barrier (depends on chemical structure) but means greater puncture and handling resistance. For products with abrasive or sharp surfaces (bones, spines, crustaceans) minimum recommended thickness is 80-100 µm PA/PE.

• 60 µm PA/PE: standard for products without sharp surfaces
• 80-100 µm PA/PE: bone-in meat, fish, abrasive products
• 120-150 µm: heavy products > 3 kg or high puncture risk
• Skin film: 50-70 µm + rigid barrier bottom film

Food contact certifications and compliance

All food-grade films must comply with EU Regulation 10/2011 on plastic materials and articles intended to contact food (MOCA), EU Regulation 1935/2004, and for recycled plastics, EU Regulation 2022/1616. Always request the Declaration of Conformity (DoC) from the film supplier and the Declaration of Compliance for the specific food contact type (fatty, aqueous, acid, alcoholic).

• EU Reg. 10/2011: general compliance for plastics in food contact
• EU Reg. 1935/2004: general MOCA framework
• FDA 21 CFR: requirements for US market
• BRC/IFS certification for film supplier: retail requirement
• DoC for each film structure: mandatory for quality audits