Flexible packaging earns its name not just from its form, but from its engineering flexibility. For manufacturers, the value lies in the ability to tailor polymer structures, barrier layers, and seal technologies to protect the product, run efficiently on existing equipment, and support evolving sustainability goals.
At Kendall Packaging, we work with manufacturers who understand that there is no single “best” material—only the best-fit structure for a specific product and market. Here’s how to think about polymer and seal customization, with a practical look at when compostable or recyclable flexible films make the most sense.
Before selecting a sustainability pathway, manufacturers should define what the package must do:
- Protect against moisture gain or loss.
- Limit oxygen exposure to preserve freshness, color, and flavor.
- Retain aroma for spices, coffee, or botanicals.
- Maintain seal integrity through distribution stresses.
These requirements determine how much design flexibility exists—and which sustainability options are realistic without compromising shelf life.
The Polymer Toolbox: Building Blocks You Can Customize
Flexible packaging structures typically combine polymers such as polyethylene (PE) and polypropylene (PP), often with barrier layers where needed. Manufacturers can develop these structures to achieve:
- Moisture resistance and toughness
- Controlled oxygen transmission for shelf-life stability
- Seal compatibility with existing filling equipment
Barrier layers like EVOH can be incorporated thoughtfully, especially in recyclable PE-based designs, when balanced against recyclability guidance.
Seal Technology: Where Performance Meets Productivity
Seal design is often underestimated, yet it directly affects…
- Line speed and uptime
- Scrap rates
- Distribution durability
Manufacturers can target specific seal characteristics such as:
- Low seal initiation temperature (SIT) to support faster cycles.
- Wide seal windows to reduce sensitivity to process variation.
- Hot tack strength for vertical form-fill-seal applications.
A well-matched seal structure improves efficiency while supporting sustainability by minimizing waste.
Recyclable Flexible Films: Where They Excel
Recyclable flexible packaging—most commonly PE-based mono-material structures—offers broader performance capability and compatibility with existing recycling pathways. Best-fit products include…
- Dry goods and powders
- Frozen foods
- Snack foods and pet treats
- Multi-serve products requiring resealability
In the U.S., store drop-off recycling is the primary recovery pathway for flexible film, making PE structures the most practical option when recyclability is the priority.
The Kendall Packaging approach
Kendall Packaging helps manufacturers engineer packaging systems—not just select materials. By aligning polymer choice, seal performance, and end-of-life strategy, we help brands protect products, improve operational efficiency, and support realistic sustainability goals.
The flexibility of flexible packaging lies in making informed, product-specific decisions—and that’s where customization delivers the most value. Kendall Packaging and our teams of experts are here to help with it all.
Let’s talk about how we can help your brand. To learn more about flexible packaging solutions tailored to your product and process, email info@kendallpkg.com.