The transition from rigid to flexible packaging: Benefits and considerations
New innovations, legislation and a requirement to demonstrate continual improvement are driving companies to upgrade their packaging. You may be considering changing to a different form of packaging, for example, from rigid packaging to flexible packaging, in a bid to lightweight your packaging, provide a better consumer experience or refresh your branding.
A new packaging solution can help your company set itself apart from competitors and has other long-term benefits. This blog highlights some challenges posed by rigid packaging and how they can be overcome by migrating to a flexible packaging solution.
Rigid Packaging Constraints - Storage, Transport, and Recycling Hurdles
Rigid packaging poses several challenges in terms of production process times, weight of the product, ease of transportation and on-shelf space and visibility. With a demand for faster delivery, greater shelf-life and consumer convenience, rigid packaging is failing to meet consumer expectations, as discussed below.
- The environmental impact – some rigid containers, such as hard plastic trays or Styrofoam containers, pose difficulties when it comes to recycling.
- Transportation and space – due to the inflexible nature of rigid materials, packaging solutions made from materials such as glass, metal, rigid plastics and cardboard take up a large area of space for storage and transportation. This also means a greater number of journeys are required to transport products, resulting in higher storage and transportation costs.
- Weight of the overall product – raw materials are used in greater quantities and rigid materials are naturally heavier and bulkier than flexible packaging. In addition, for fragile rigid packaging such as glass or cardboard, secondary packaging is usually required to protect the product from impact during transportation and delivery which adds additional processes, weight and cost.
Why Switch to Flexible Packaging? It’s Lighter, Safer, and More Efficient
Flexible packaging can be a great alternative to your existing rigid packaging, it offers several advantages. Switching to flexible packaging means –
- Lighter packaging while maintaining protection – fewer raw materials are used during manufacture for flexible packaging, therefore the packaging remains light but still offers strength. By using different combinations of flexible films, you can have puncture and impact resistant packaging that also has barrier properties to control and retain moisture, aroma and texture levels and prevent cross-contamination.
- Transportation and storage – flexible packaging makes storage and transportation easy as the products are light, occupy less space and robust enough to withstand the rigours of the supply chain.
- Addressing consumer needs – convenience is an important driver for retailers and consumers. Flexible packaging opens a world of consumer-friendly options such as resealable, ovenable and portable solutions with improved shelf-life, and the opportunity for eye catching packaging that enables consumers to easily identify the product whether in the ambient, chilled or frozen section of the store.
As new technologies emerge in flexible packaging, it is fast becoming the ideal choice for modern packaging solutions. At a CAGR (compound annual growth rate) of 6%, the industrial films market is set to expand to $57 billion by 2028.
Step-by-Step Guide: Transitioning from Rigid to Flexible Packaging
When deciding whether to transition from rigid to flexible packaging there are a number of different factors to consider. This is a handy checklist.
- Versatility of the contents of the product – Consider the nature and properties of the contents that go into the flexible packaging. PE films have great moisture barrier properties that make them ideal for storing food and beverages. For packaging food that needs to be microwaved or be placed in the oven, lidding films with hot needle perforation are a good solution.
- Added benefits – consider the additional benefits that flexible packaging might offer throughout the manufacturing process such as speed, reduced cost and flexibility. For example, flexible packaging can eliminate the need for additional processes such as capping and flexible pouches can withstand hot or cold liquids produced during the manufacturing process, eliminating waiting times and increasing productivity.
- Size and shape of your product – consider the size of the contents as well as the size and shape of the product after packaging. Flexible films are easily converted into bags and pouches with versatile shapes and value-added features that fit the packaging closely around the contents, thus reducing the overall size.
- Aesthetics – flexible films can be made opaque or transparent to show off or conceal the contents and some films, like OPP films, can be metallised or laminated, to add visual appeal or extra protection.
- Freshness and shelf-life – if you are considering how to keep contents safe and fresh on shelves for a longer period of time, barrier films are a perfect solution. They can maintain an ideal balance of moisture and gases, help keep out microorganisms and reduce cross-contamination of the contents to boost shelf-life, maintain freshness and retain the perfect texture.
- Lifestyle choices – add value to products for consumers. Flexible packaging can be customised to create consumer-friendly options such as smaller pouches for portion control, which appeal to modern shoppers. PET films are used to create peelable and resealable packaging, helping smaller households avoid product wastage. Stand-up pouches are a great portable option.
- Innovation and branding – highlight the innovative features of your products through the design and printing of the packaging. Help capture consumer attention with vibrant flexographic print and high-quality design that enhances the look and feel of your product. Flexographic films are so versatile they can be designed to appeal to your target audience whether your brand identity is fun, fresh, natural, artisan or luxury.
Careful planning at the design stage will ensure a successful and smooth transition from rigid to flexible packaging so that you can reap the many benefits from design, production process, storage and delivery through to consumer purchase and use. Choosing the right team of technical experts to manage your flexible packaging project will help you navigate the re-development from design to technical specification to printing and supply.
Unlock the Benefits of Flexible Packaging with Terinex Flexibles
As a leading supplier of printed flexible packaging films, Terinex Flexibles provides cost-effective and sustainable solutions for packaged goods. To create a comprehensive transition plan to flexible packaging and enhance your packaging with value-added services including design and printing, set up a call with us!
