Problems and Risks of Flexible Packaging for Food Products

Introduction

Flexible packaging is a powerful solution for food brands—but only when risks are proactively managed. This page details common pitfalls and how to address them. For overall benefits and context, see the complete food packaging guide.

Key Risks to Manage

• Barrier performance: Choose structures validated for your moisture/oxygen and aroma needs.
• Perception: Premium design and finishes can elevate flexible formats for gourmet categories.
• Supply volatility: Forecast resin trends and build buffer inventory for critical SKUs.
• Sustainability: Match claims to local recycling/compost access and communicate clearly.

How Risks Affect Cost

• Product spoilage from inadequate films creates waste and lost revenue.
• Negative perception can reduce sell-through despite lower packaging cost.
• Material volatility complicates budgets and pricing strategy.
• Misleading claims can cause compliance or reputation issues.

Mitigation Checklist

• Lab and shelf testing for barrier and seal integrity.
• Design for your target perception: finish selection, window placement, graphics.
• Dual-source or plan lead times on critical films.
• Be precise and transparent on sustainability messaging.

Compare risks across formats in our format comparison.