For brands that deal in bars, baked goods, confectionery, personal care, or medical products, flow wrap packaging offers a powerful combination of speed, protection, and visual polish. It’s sleek, efficient, and adaptable to a wide range of industries. But not all flow wrap is created equal. To truly perform—both on the shelf and in transit—your packaging must be engineered to guard against contamination, preserve freshness, and deliver a clear brand message.
Whether you’re scaling a legacy product or launching a new SKU, smart packaging design begins with the right features and materials.
Tamper-Evident Seals and Moisture-Resistant Films
When consumers pick up a wrapped product, they’re trusting that what’s inside is clean, safe, and intact. The right flow wrap structure reinforces that trust.
1. Tamper-evidence builds consumer confidence
Adding tamper-evident seals or perforations to your flow wrap protects the product and assures customers that it hasn’t been opened or altered. This is especially important for food, pharmaceuticals, and beauty products where safety and hygiene are non-negotiable.
2. Moisture and oxygen barriers preserve quality
Nothing ruins a protein bar or cookie faster than exposure to moisture. High-barrier films prevent spoilage by locking out humidity and oxygen, which can lead to sogginess, oxidation, or loss of potency. This is the same technology used in custom mylar bags, adapted to the needs of flow-wrapped products.
3. Precision sealing ensures integrity at scale
Flow wrap machines are designed for high-volume, high-speed output—but if the material isn’t engineered for strong, reliable seals, it can lead to waste, spoilage, and costly rework. Choosing the right film structure and sealing properties can make or break your production efficiency.
Choosing the Right Material: PE, BOPP, PET, and Sustainable Options
Material selection isn’t just about protection—it’s about aligning with your product’s specific needs, your brand values, and your audience’s expectations.
1. Polyethylene (PE)
PE is flexible, durable, and a popular choice for primary food contact. It’s often used as a sealing layer in multi-layer films and works well for snacks and personal care products. PE is also compatible with certain recyclable and monomaterial applications.
2. Biaxially Oriented Polypropylene (BOPP)
Known for its glossy finish and clarity, BOPP offers excellent stiffness, printability, and moisture resistance. It’s a favorite for high-speed packaging environments and performs well for products that need a premium look and tight wrapping.
3. Polyethylene Terephthalate (PET)
PET adds strength and heat resistance, making it ideal for products that need more protection or a more rigid structure. It also serves as an effective oxygen barrier when layered with other materials.
4. Sustainable film options
More brands are looking to reduce their environmental impact without sacrificing performance. ePac offers recyclable and post-consumer recycled content options to help you align with sustainability goals—without compromising visual quality or shelf life.
Flow wrap is just one piece of the packaging puzzle. For resealable formats or stand-up displays, custom stand up pouches may be a better fit. But when it comes to single-serve, high-speed packaging with visual impact, flow wrap delivers.
Designing effective flow wrap packaging means balancing performance and promotion. With the right materials and structure, your packaging can protect your product—and elevate your brand—all in one seamless solution.