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How to protect your product

Protecting your product

Packaging has one primary function: protecting the product. Without proper protection, a product can be damaged or spoiled during transport, storage, or use. This leads to waste, extra costs, and a greater environmental impact.

In sustainable packaging design, protection plays a central role. A package that doesn’t provide enough protection is ultimately less sustainable, even if the material is fully recyclable.

On this page, you’ll learn how protection works, which factors play a role, and how you can estimate which type of packaging best matches your product’s needs.

Protect your product with safe stand-up pouches

How packaging protects your product

Packaging fulfills several protective functions. Depending on the type of product and its intended use, different features may be important. Below are three key aspects:

Barrier properties

Many packages consist of multiple layers that protect the product against external influences such as oxygen, moisture, light, or odors. These barrier layers help extend shelf life and preserve product quality. Their effectiveness depends on the material and structure of the packaging.

Physical protection

Packaging also needs to protect against physical stress, such as impacts, pressure, or drops. This is especially important for fragile or sensitive products. Flexible packaging can absorb some of these forces, helping to reduce damage during transport or storage.

Closures and convenience

Packaging doesn’t just protect during transport or storage, but also during use. Closure systems such as zippers, seals, or valves can prevent air, moisture, or other substances from affecting the product after opening. They also improve ease of use and help reduce waste.

Protection and sustainability: finding the right balance

When it comes to sustainable packaging, the focus is often on materials: is it recyclable, compostable, or made from renewable resources? But that’s only part of the story. Packaging also plays a crucial role in protecting products from damage, spoilage, or quality loss. If protection falls short, the resulting waste often has a much bigger environmental impact than the packaging material itself.

Take coffee as an example. Producing one kilogram of coffee beans requires around 18,900 liters of water. To package that kilo of coffee, a flexible pouch of about 25 grams of film is enough. Producing that amount of plastic requires less than 0.05 liters of water, based on an average water footprint of 183 liters per kilogram of plastic.

If coffee isn’t properly protected against oxygen or moisture, it can lose quality or spoil. If the product has to be thrown away, not only the packaging is wasted, but also the thousands of liters of water, energy, fuel, and labor that went into production and transport. In this light, packaging that doesn’t fully meet recycling standards but provides long-lasting protection may actually be the more sustainable choice.

Protect your product with sustainable stand-up pouches

Protect your product with safe packaging

This challenge also applies to other product groups such as meat, nuts, dairy, or pharmaceuticals. In these cases, the environmental impact of the product itself is often higher than that of the packaging, making functional design more important than material choice alone.

In short: the most sustainable packaging is not always the one with the lowest material use or the best recyclability, but the one that fits the product’s characteristics and risks. Sustainability is about balancing protection, material, usability, and processing—and that balance differs per situation.

Making the right choice yourself

Not sure what’s best for your product? Feel free to get in touch with us. We’re happy to share our knowledge and experience, so we can work together on a solution that matches your product and provides the protection it needs.

Looking for a quick answer? Check out our FAQ!

Protect your product

What level of protection (barrier) does your product need?

There are different barrier materials, such as aluminium, kraft paper and multi layer films. Your choice depends on how sensitive your product is to oxygen and moisture. The more sensitive it is, the stronger the barrier should be. Get advice and choose the solution that fits your product and your recycling goals.

Is using less material always more sustainable if protection decreases?

Not always. Less material can seem more sustainable, but if the packaging does not protect your product well, the product may be wasted. Product waste often has a bigger environmental impact than the packaging itself. So always choose the right balance between material reduction and product protection.

Do a zipper or valve also contribute to protection?

Yes. Zippers and valves help keep your product fresh for longer and help prevent leakage. They improve protection, especially when the pack is opened and closed repeatedly. Make sure they match the material of your pouch, so recyclability stays intact.

What should you consider for light or heavy products?

The weight of your product helps determine which packaging you need. Light products usually work well in standard flexible packaging, such as snacks, powders or dried ingredients. Heavier products, like liquids, bulk goods or pet food, require stronger materials. This often means thicker films or an extra layer, such as nylon, to prevent tearing or sagging. For heavier contents, also check seal strength, bottom construction and the type of closure. Everything must handle the weight and stay safe during transport. Testing is key, feel free to request samples.

How do you test if your packaging can handle impacts, for example during transport?

There are several test methods to assess physical strength. The most common are: drop tests, which simulate drops during transport, and compression tests, which measure how well packaging resists stacking or crushing. These tests help you judge whether your packaging protects your product well, even under tough conditions.

How do I handle extreme conditions during transport, high humidity and temperature changes?

Transport can be demanding. Think high humidity, temperature swings or rough handling by carriers. Watch these risks: moisture and condensation, choose water resistant materials or sealed packaging. Temperature changes, use a structure that stays stable in heat and cold. Physical stress, carriers stack, slide and sometimes drop boxes. Your packaging should handle shocks, pressure and abrasion, often checked with a drop test. Make sure your packaging is tested for these situations. We are happy to advise on a solution that helps your product arrive safely.

How do you know what protection your product needs?

It depends on how sensitive your product is to air, moisture, light or odours. Ask yourself: does it lose taste or aroma quickly, choose a high oxygen barrier, such as EVOH or aluminium. Does it get soft or clump due to moisture, choose a moisture barrier film. Is it sensitive to light, consider an opaque or metallized layer. Do you want it to remain recyclable, a mono PE or mono PP with a light barrier coating is often the best choice. Not sure? Contact one of our specialists, we are happy to help.

How do you choose packaging that both protects and is sustainable?

Today, there are recyclable and compostable packaging options with strong barrier performance. This keeps your product protected and supports a more sustainable packaging process. Ask for advice to find what fits your product and your sustainability goals.

Is too much protection bad for the environment or costs?

Yes. Overpackaging can be negative. A barrier that is stronger than needed often uses extra material, which can mean higher costs, more difficult recycling and more environmental impact. Do not choose “as strong as possible”, choose “strong enough”. The right balance saves material and money.

How does PouchDirect help you choose the right packaging?

Our packaging specialists think along with you and support you personally to find the best solution. We look at your product properties, your logistics process, the required shelf life, your sustainability goals and your budget and brand experience. Together we find packaging that not only looks good, but also truly works, practical, sustainable and customer focused.

What does extra product protection in packaging cost?

Packaging with extra protection or special materials can be priced slightly differently, but it brings direct benefits: less waste, longer shelf life and less product loss. In the long term, it is often cost saving and better for the environment.

How are protective properties of packaging tested?

There are international tests and standards that measure barrier and protection levels objectively. Key examples: OTR, Oxygen Transmission Rate, measures oxygen permeability. WVTR, Water Vapor Transmission Rate, measures moisture transmission, crucial for shelf life. Migration tests, according to EU 10/2011, check whether substances migrate from packaging into food. Shelf life tests simulate the shelf life of the final product, usually done by the customer with the product. Drop and compression tests, ASTM and ISTA, test physical strength during transport. Many tests follow standards like ISO, ASTM, DIN or EN. We ensure our packaging is tested for technical barrier properties. For product specific testing such as shelf life or drop and compression tests, we advise you to collaborate with your own lab or product developer.

Can I request samples to test the packaging in practice?

Yes. We are happy to send samples so you can test: filling and sealing, barrier performance, ease of use, appearance and printing, and suitability for your product. This way you can verify whether it works in your process and for your customers. Request samples via our website or contact one of our pouch specialists.What often goes wrong when designing protective packaging?Avoid the most common mistakes. Good packaging protects your product and fits your process. Watch out for: too little barrier, your product spoils faster or loses quality. Wrong closure, choose zippers or valves that seal well and match the material. Unnecessarily heavy material, more layers than needed increase costs and hinder recycling. No transport check, thin films or weak seals can tear or leak. Not tested in practice, lab data alone is not enough. Test smart and practical: do a shipping trial, pack your product ...

Stand up pouch vs rigid packaging, glass, can, carton: which protects better?

A stand up pouch can protect extremely well when you choose the right barrier and closure. Focus on: protection against air and moisture, the right structure keeps your product fresh. Protection against light, choose an opaque or metallized layer if light is harmful. Resistance to impacts, drops and stacking, use the right film thickness, strong seals and a stable bottom. Good reclosure, use a zipper, valve or spout for leak tight opening and closing. Heating during production, if you pasteurize or sterilize, choose a retort pouch. Practical checks: request samples, test seal strength, do drop and stacking tests and run a short shipping trial.

What often goes wrong when designing protective packaging?

Avoid the most common mistakes. Good packaging protects your product and fits into your process. Keep the following in mind: Insufficient barrier: Your product spoils more quickly or loses quality. Incorrect closure: Choose zippers or valves that seal well and are compatible with the material. Unnecessarily heavy material: More layers than necessary increase costs and hinder recycling. No transport check: Too thin film or weak seals tear or leak during transport. Not tested in practice: Lab data alone is not enough. Test smartly and practically Do a shipping test: Package your product and send it to yourself. See how it arrives. Check sealing and barrier: Fill, seal, shake, stack and drop (drop test light). Evaluate with your team: Note any issues and make targeted improvements. Need help? We're happy to assist! Our experts provide personalised advice and deliver samples. This...

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