OTR (Oxygen Barrier): What Is It and Why Does It Matter?
For products that are sensitive to oxygen, choosing the right packaging is essential. Think of coffee that needs to keep its rich aroma or nuts that should stay fresh and crunchy. To protect your product's colour, aroma and flavour, one of the key things to look at is the packaging's OTR value.
What is OTR?
OTR stands for Oxygen Transmission Rate. It measures how much oxygen can pass through a packaging material over a certain period of time.
OTR is usually expressed in cm³ of oxygen per m² of packaging material per day, under specified test conditions.
Even a sealed plastic pouch can allow small amounts of oxygen to pass through the material over time. Think of a balloon that slowly loses air after a few days. Packaging films work in a similar way: most materials aren't completely impermeable, but the right barrier can significantly slow down oxygen transmission.
How do you interpret an OTR value?
Low OTR: Very little oxygen passes through the packaging. Ideal for products that need to stay fresh for longer.
Higher OTR: More oxygen can pass through the packaging. This may be suitable for certain fresh products with a shorter shelf life.
The lowest possible OTR isn't always necessary. The right level of protection depends on your product and how long you want it to stay fresh.
Do you always need an OTR of 0?
Customers sometimes ask whether their packaging needs to be completely airtight to oxygen.
Traditional aluminium foil laminates can offer an extremely high oxygen barrier, with OTR values that may be reported as zero under specific test conditions. But for most products, that level of protection simply isn't necessary.
So don't be put off if you see an OTR or WTR value of 2 or 3 in our technical specifications. Depending on the material, test conditions and application, these can still represent excellent barrier performance.
For products such as coffee, nuts and powders, a low OTR can help preserve freshness and extend shelf life. The exact shelf life, however, depends on more than just the barrier value.
Choosing an extremely high barrier when you don't need one can also mean additional costs or fewer material options. The aim is to find the right balance between product protection, packaging performance and sustainability.
Why is an oxygen barrier important?
When oxygen comes into contact with your product, it can cause oxidation. This process can affect flavour, aroma, colour and texture.
For products containing natural fats and oils, a good oxygen barrier helps prevent unwanted changes in taste. For coffee, it helps preserve those distinctive aromas that make every blend unique.
Choosing packaging with a suitable OTR helps slow down oxidation and keeps your product in better condition for longer.
Products that often benefit from a low OTR include:
Coffee beans and ground coffee
Nuts and seeds
Crisps, crackers and other snacks
Dried fruit
Tea, herbs and spices
Food supplements and protein powders
Cosmetic and pharmaceutical products
Is OTR the only factor affecting shelf life?
A good oxygen barrier is an excellent starting point, but it's only part of the picture. Water vapour transmission rate (WTR), seal quality, the use of valves and storage conditions also affect how well your packaging protects its contents.
Even the best barrier film won't perform as intended if the pouch isn't sealed properly.
Oxygen barriers and recyclable packaging
Want more sustainable packaging without compromising on product protection? It's possible.
Recyclable packaging can also offer excellent oxygen barrier properties. Performance depends on the material structure, barrier technology and film thickness.
At PouchDirect, we help you find packaging that offers the protection your product needs while supporting your sustainability goals.
✔ Free shipping from €500.00
✔ Ordered before 15:00, shipped the same day
✔ Europe's largest stock
Our approach: Test before you decide
You'll find the OTR and WTR values in the technical specifications of our packaging. This makes it easier to compare different options and choose the right level of protection for your product.
Technical specifications are a great starting point, but real-world testing matters too. We're happy to help you find packaging with the right oxygen barrier for your product. Request samples and see how well your product maintains its freshness, aroma and flavour.
That depends entirely on your product. A lower OTR value provides better protection against oxygen, helping to extend shelf life. Let's find out together which OTR value best suits your packaging needs.
Do all packaging materials have the same OTR value?
No. The OTR value depends on the material, its thickness and the barrier layers used. Temperature and humidity also play a role. Learn more about our packaging materials.
Are there recyclable pouches with a low OTR value?
Yes! There are recyclable pouches that offer good oxygen protection and help keep products fresh for longer. Explore our recyclable pouches and discover the possibilities.
