Types of Food Packaging Materials Explained: A Complete Guide

The packaging material to be used for your food products isn't simply about looks or cost. It's a crucial choice that influences food safety, good shelf life, your brand's image and, more and more, the environment's expectations of your business.

Having worked with food manufacturers, retailers and food startups for 15 years, I have witnessed the impact of the right food packaging material choice for a product that comes fresh onto the shelves versus a product that goes bad on the shelves. Our forefathers used clay pots and wooden barrels in those days. Nowadays, everything from high-tech biodegradable films to real-time freshness tracking intelligent packaging are available.

This guide takes you through each and every major packaging category - what works, what doesn't, and the multitude of packaging options available today.

Understanding Food Packaging Levels

There are three levels of food packaging and it's important to know about them so you can make better choices:

Primary Packaging is the packaging that comes in direct contact with your food. This is you're paper bags, plastic wrap or jar lids. It has to satisfy strict food safety regulations since it is the first line of defence between your product and the consumer.

Secondary Packaging is the process of combining primary packages into groups for consumer convenience and branding. Imagine a box of cardboard with several bottles in it or a box of cardboard with each snack package in a separate segment. Here is where brands develop acknowledgment.

Tertiary Packaging shares the product between point A and point B; between the warehouse and trucks, from trucks to stores. This level is dominated by heavy-duty corrugated sheets and shipping boxes. Durability and stackability are the most important attributes for logistics teams.

Types of Food Packaging Materials

Choosing the wrong material can cost you customers, compliance, and product quality all at once 

Plastic

Plastic is the most flexible packaging material used in food production, but is under review.

Subtypes include:

• PET (Polyethylene Terephthalate): Your water bottles and soda containers
• HDPE (High-Density Polyethylene): Milk jugs, detergent bottles
• LDPE (Low-Density Polyethylene): Flexible films and squeeze bottles
• PVC (Polyvinyl Chloride): Cling wrap and some rigid containers
• PP (Polypropylene): Yogurt containers, snack packaging
• PS (Polystyrene): Takeout containers, foam packaging

Plastics are excellent barrier properties as they are resistant to moisture, oxygen and light. They are reasonably priced and lightweight, which helps to keep shipping costs down. However, environmental issues remain a serious consideration. Plastic never breaks down and micro plastics are being discovered in ecosystems and food chains.

Cons: Prone to damage, cannot be fixed or patched when holes are found in the roof.

Pros: No harm to the skin, no known allergens, non-toxic to the environment, and non-toxic to humans.

Metal

The metal packaging, which is mainly made up of aluminum and steel, provides superior protection, premium position.

Aluminum is used in foils to wrap and as cans for drinks. Completely and effectively blocks light and oxygen, suitable for light-sensitive products. Traditional canned goods and metal closures are made from tin-plated steel. Specialty containers and food-service uses are made of stainless steel.

Metal is fully recyclable infinitely without quality loss. An aluminum can make 60 days on the shelf, before returning to shelves. The production of metals, however, is energy consuming and in some cases, the barrier properties are too high for the product.

Cons: Can be reused, light proof and a superior feel.

Pros: Easy to use, low cost, energy efficient, over-specified for many uses

Glass

Glass is the tried and tested material for food safety – it is inert, leaching free and forever.

Borosilicate glass is resistant to high and low temperatures (like lab beakers, oven-proof containers). A common type of glass used for jars and bottles is soda lime glass. Glass is clear so the consumer can see the product and indicates premium quality.

Heavier than alternatives, thus adding to shipping emissions. It also can break and poses safety and waste issues. With oil, sauces, condiments and premium juice brands, however, the drawbacks of glass are outweighed.

Cons: High price, limited applications, high level of skill required, requires a significant amount of training, not suitable for the home market,

Pros: Greater strength, break resistance, lower manufacturing energy (and cost), shipping cost benefit.

Paper and Paperboard

Brands are rethinking toward sustainability, giving rise to a resurgence of paper-based solutions.

Kraft paper is strong, versatile and is offered in natural brown or bleached white. Secondary and tertiary packaging is provided with corrugated cardboard to give the structure. Examples of folding cartons include cereal boxes which provide protection and brand. For applications such as frozen foods or wet applications, coated paperboard provides additional moisture-resistance.

For dry products, take-out containers and secondary/tertiary packaging, paper and paperboard are ideal. Corrugated packaging is the driving force behind ecommerce fulfillment. White paper bags and brown paper bags are used for retail, food service and gift applications.

Cons: Chemical, physical or biological processing may be needed to recycle, compost, or use as a renewable resource, expensive to use for branding applications.

Pros: Good barrier properties, durable, moisture resistant, Needs coating for certain food applications

Cellulose-Based Materials

The materials used are derived from plants and thus fall between plastic and paper.

Cellophane is a clear film, based on wood pulp. It's biodegradable and compostable. Cellulose acetate offers barrier properties, without using petroleum derivatives. These materials are not bioaccumulating as conventional plastics are, and decompose within months in industrial composting.

They make great snacking options, dry foods, and high quality placement. They are however more expensive than regular plastics and not every area will have the composting system.

Cons: Not recyclable, requires a long time to degrade

Pros: Lower cost, superior barrier properties to plastic, composting infrastructure dependable

Ceramics

Ceramics fit into a niche – primarily in the high priced tea market and specialty food market. They are beautiful, inactive and can be recycled completely, but are also heavy and fragile. Ceramics don't have the volume of corrugated boxes or paper bags, but it's not to say that they don't attract loyalty in certain categories.

Biodegradable and Compostable Materials

This is where sustainable food packaging and eco-friendly food packaging really sets you apart.

PLA (Polylactic Acid) comes from corn starch or sugarcanes. It appears and feels like plastic, but breaks down at industrial composting sites. Bagasse is sugarcane pulp which remains after the juice is extracted: strong, functional and compostable. Mushroom packaging is made using the mycelium as a glue, which is 100% home compostable. Some applications allow the use of seaweed films that are edible and fully marine biodegradable.

Certifications matter here. Search for the European (EN 13432) or the American (ASTM D6400) compostability standards for real compostability. There are many "biodegradable" products that will not degrade in the environment.

Pros: Reduced environmental impact, aligns with consumer values, compostable, innovative positioning

Cons: Expensive, some materials have reduced shelf life, certification may be complicated, requires infrastructure

Active and Intelligent Packaging

Oxygen scavengers are added to remove oxygen that causes degradation to the product, and thus extend shelf life. Dry goods are kept nice and crisp by moisture absorbers. Antimicrobial liners are used to prevent the growth of pathogens. Smart labels are the ones that change colour when they start to go bad. QR code freshness indicators connect to real-time tracking of product where it is being used, providing traceability from factory to consumer.

These solutions address real problems—spoilage, recalls, food waste—but add cost. They're increasingly essential for premium products and regulated sectors like pharmaceutical-grade supplements.
Material Comparison Table

How to Choose the Right Food Packaging Material

When deciding which material to use, you need to consider several things:

Barrier Properties: what needs to be protected from your product? Moisture? Oxygen? Light? Grease? A dry snack requires less barrier than an oil-based dressing. The food packaging solutions vary greatly according to these requirements.

Different food types have different requirements; dry goods, wet products, acidic foods, frozen products, and hot-fill applications all have different requirements. The ideal food packaging material for pasta will not be suitable for tomato sauce.

Shelf Life Requirements: Product requiring a 24 month shelf life will require greater barriers (most likely metal or coated plastic) than a product with 3 month shelf life.

Regulatory Compliance: FDA food contact substance guidelines and EU Regulation 1935/2004 have strict regulations for chemical migration. Failure to comply results in recalls and damage to brands. Make sure your packaging materials for food are approved for the region in which you're packaging.

Sustainability Goals: Will you be appealing to eco-conscious consumers? Sustainable food packaging and eco-friendly food packaging are now impacting buying decisions, particularly in the younger generations.

Product Costs: The higher initial costs of premium materials (glass and advanced compostables) can also provide improved margins and premium positioning.

Food Packaging Regulations and Safety Standards

This is non-negotiable. I have seen good-intentioned startups get recalled due to non-conformance.

Food contact substances are defined by FDA food contact substance guidelines, which prescribe what materials and inks may be in contact with food, and what concentrations are acceptable. Previously commonplace, BPA (Bisphenol A) is now curbed significantly. EU Regulation 1935/2004 is even more demanding and forbids the use of some plasticizers.

Migration limits are used to limit the amount of chemical residue that can leach into food from packaging. These restrictions apply to different foods and packaging. Independent food-grade certification from labs is proof of compliance.

The non-compliance will not only result in fines, it is also the death of a brand. Do the right test before going to market.

Sustainability and the Future of Food Packaging

The packaging world is changing, and we are not fully aware of it.

Single-use plastic bans have been implemented in the EU, Canada and many other countries. The U.S. is going state-by-state. Single use plastics are not the solution if your supply chain is based on them.

Adopting the circular economy is now commonplace business practice, meaning that materials can no longer be discarded in landfills. In recent years, laws toward extended producer responsibility (EPR) have been established, obliging manufacturers to finance the end-of-life management of their packaging.

New materials such as 'mycelium materials' (materials formed by mycelium), algae films and even edible packaging are being taken from the laboratory to mass production. Ocean-friendly, plant-based products are no longer a specialty, but an expectation.

Consumer expectations have also changed. Brands that make public statements about sustainability benefits enjoy loyalty premiums.Loyalty premiums for brands announcing sustainability benefits. Any competitors who do not stick to sustainability get backlash on social media.

Cost Breakdown: Material vs. Long-Term Value

The lowest cost package does not necessarily equate with lowest total cost.

A corrugated box is cheaper to make initially compared to a solid box, but if your product breaks on the way, all the benefits of a box go down the drain in terms of refunds and consumer satisfaction. Paper bags are good for dry commodities, but are not suitable for humid climates where they can spoil.

Determine TCO: Material costs + shipping weight impact + spoilage rates + returns/refunds + brand positioning value. While glass packaging may be 3x as expensive per unit, a 20% price premium will offset the loss in spoilage from 8% to 1%.

Premium materials—glass, active packaging, compostables—justify their cost through:

• Reduced product loss
• Higher retail prices
• Enhanced brand loyalty
• Regulatory future-proofing
• Marketing differentiation

Conclusion

Packaging selection is not a 'one size fits all' process. It needs to take account of food safety, shelf life protection, cost, sustainability, and regulations.

The most successful brands don't seek the lowest price—they invest in packaging that is problem solving to prevent spoilage, reinforces brand, complies with regulations and pleases customers.

Your packaging is often the first physical touchpoint with your customer. Make it count.

Looking to improve packaging? Talk to a packaging expert or use our material comparison guide to discover the differences between various food packaging materials and food packaging solutions for your specific packaging application.

Frequency Ask Questions

1.  What is the safest food packaging material?

Glass is chemically inert and transfers zero compounds to food. Metal (aluminum, stainless steel) is equally safe. Some plastics (PET, HDPE) are safe when properly manufactured, but glass eliminates uncertainty.

2.  Which packaging material has the lowest carbon footprint?

Recycled paper and cardboard (especially with recycled content) have lower footprints than virgin materials. For non-paper, lightweight plastic minimizes transportation emissions, though it creates end-of-life problems. Locally sourced materials beat imported solutions regardless of material type.

3. Is biodegradable packaging always better?

Not necessarily. Biodegradable materials that can't access composting infrastructure just create guilt-free littering. A long-lived, infinitely recyclable aluminum can beats a "compostable" PLA package sitting in a landfill. Context matters.

4.  What packaging materials are banned in the EU/US?

The EU bans expanded polystyrene (foam) containers, single-use plastics, and certain BPA/phthalate combinations. The US has state-level bans on specific plastics but no comprehensive federal ban. Check jurisdiction-specific regulations.

5.  Can recycled materials be used for direct food contact?

Yes, but with restrictions. Recycled content is increasingly approved for food contact, but only through certified processes. The EU allows recycled plastic in food contact under strict conditions; the US is more restrictive, limiting most recycled plastics to non-food or indirect contact.