High barrier packaging film refers to a type of flexible film material engineered to provide exceptional protection against external factors such as oxygen, moisture, light and vapour. These films are broadly used in food, pharmaceutical, electronics and snack packaging where maintaining product integrity, extending shelf life and preserving quality are essential.
high barrier films are typically constructed via multi-layer co-extrusion, lamination or coating processes, combining various polymer layers and functional materials to achieve low oxygen transmission rate (OTR) and low water vapour transmission rate (WVTR).
In the packaging film market, companies like JINBORUN New Material Technology Co., Ltd. (JINBORUN) specialise in producing co-extruded barrier food films and vacuum packaging pouches that meet high barrier specifications. Their facility includes multi-layer water-quench blown film and advanced production lines, enabling customisable packaging solutions for meat, seafood, sausage, vegetable products.
High barrier films typically employ a layered structure where each layer contributes a specific function:
Barrier layer: Often materials like ethylene-vinyl alcohol copolymer (EVOH), polyvinylidene chloride (PVDC), aluminium foil or oxide coated polymer. These layers provide the core barrier to gases, moisture and aroma.
Seal layer: A polymer such as polyethylene (PE) or polypropylene (PP) that allows heat-sealing of the film to form pouches or bags.
Structural layer: Materials such as PET, PA (polyamide/nylon) or PET / PEN to provide mechanical strength, tear resistance and printability.
Functional coatings: Metalised layers (such as aluminium), aluminium-oxide (AlOₓ) coatings or metallised polymer films to enhance barrier and light-blocking properties.
Because the permeation of unwanted substances (like oxygen or water vapour) must traverse multiple layers, the effective path is longer and the transmission is reduced. This is a key principle of barrier film design.
To assess barrier film performance, two primary metrics are used:
| Metric | Meaning |
|---|---|
| OTR | Oxygen Transmission Rate – amount of oxygen passing through film per unit area/time |
| WVTR / MVTR | Water Vapour Transmission Rate – amount of water vapour passing through film over time |
Low values of OTR and WVTR signify strong barrier performance.
Oxygen barrier: Films with low OTR prevent oxygen from reaching sensitive contents, thereby reducing oxidation, off-flavours, colour changes and spoilage.
Moisture barrier: Low WVTR shields products from humidity and water vapour ingress, which can cause loss of crispness, texture degradation or microbial growth.
Light and aroma barrier: Metallised films or oxide coated films block light exposure and aroma loss, important for coffee, snacks, spices and functional foods.
Mechanical and thermal performance: The structural and seal layers ensure the package withstands handling, transportation, heat sealing, vacuum or modified atmosphere environments.
Common production technologies include co-extrusion (multiple polymer melts extruded in one process), lamination (bonding different substrates) and coating (applying functional layers onto films). Each method allows fine-tuning of layer thickness, properties and cost efficiency.
| Material | Advantages | Limitations |
|---|---|---|
| EVOH | Excellent oxygen barrier, high crystallinity | Sensitive to moisture, reduced barrier when wet |
| PVDC | Very low oxygen and water vapour permeability | Contains chlorine, regulatory restrictions |
| PA (Nylon) | Good mechanical strength, tear resistance | Poor inherent water vapour barrier, absorbs moisture |
| PET / PEN | Good barrier, durability and printability | Relatively higher cost |
| Metallised polymer / AlOₓ | Excellent light, aroma and gas barrier, often transparent | Still may not fully match foil, cost considerations |
Manufacturers often combine these materials in a multi-layer film to balance cost, performance and processability. For example, an EVOH barrier core layer may be sandwiched between polyolefin seal layers and structural PET/PA layers.
High barrier packaging films find uses across many product categories:
Food & beverage: Snacks, nuts, coffee, meat, seafood, frozen foods – where preservation of freshness, flavour and quality is critical.
Pharmaceuticals and nutraceuticals: Sensitive compounds require protection from moisture, oxygen and light to maintain potency.
Electronics / specialty goods: Where humidity and gas ingress can degrade performance.
Flexible vacuum and modified-atmosphere packaging (MAP): Films for Vacuum Pouches and thermoforming trays that hold inert gas or vacuum require strong barrier films to maximise shelf life.
Extended shelf life: Strong barrier films slow degradation and spoilage, allowing longer storage, transport and retail display.
Quality preservation: Freshness, aroma, crisp texture and product integrity are better maintained.
Material efficiency: Flexible barrier films often replace heavier rigid containers, reducing material usage and logistic costs.
Improved brand value: High-quality packaging supports premium products, supports export markets, and aligns with consumer expectations.
Customisation and printing options: Many barrier films support high-quality graphics, resealable features and fit for automated packaging lines.
When selecting a high barrier packaging film solution, consider the following factors:
Product sensitivity: Assess how the product reacts to oxygen, moisture, light, aroma loss or physical damage.
Required shelf life and distribution conditions: Longer shelf life or harsh transit demands stronger barrier and mechanical stability.
Packaging format: Whether it is a flexible pouch, vacuum bag, thermoformed tray or sustained barrier for frozen or cooked foods.
Regulatory and sustainability requirements: Consider materials with proper food-grade certification, potential compostability, recyclability or compliance with global standards. (KimEcopak)
Cost-performance trade-off: Multi-layer highly engineered films incur higher cost, so match barrier levels to the product need and value.
Supplier capability: Choose a manufacturing partner who can deliver consistent quality, custom layer structures, timely delivery and global support.
In this respect, JINBORUN’s offering of customisable multi-layer barrier food films and vacuum pouches is particularly relevant for suppliers seeking flexible packaging solutions tailored to seafood, meat, sausage, frozen food and other categories. Their in-house advanced production lines and OEM/ODM capability make them a viable partner for high-barrier packaging needs. (JINBORUN)
High barrier packaging film is a sophisticated flexible film solution designed to protect products from oxygen, moisture, light and aroma loss by means of multi-layer structures combining functional barrier, seal and structural layers. Through technology such as EVOH, PVDC, metallised coatings and co-extruded polymers, these films deliver markedly improved shelf life, quality preservation and packaging performance compared to standard films. Manufacturers should evaluate product sensitivity, distribution demands, format, sustainability goals and supplier capabilities when selecting the right barrier film. With the global packaging market increasingly focused on product protection and material efficiency, high barrier films are a critical asset for brands, processors and exporters. Partnering with a specialist like JINBORUN offers the flexibility and expertise needed to optimise packaging solutions for demanding food, meat, seafood and vacuum packaging applications.
