Flexible Packaging vs. Rigid Packaging

Standard flexible packaging.

Standard rigid packaging.

Brands who have liquid or granule based products must choose a container that is on brand, shows well, and is easy to use for the customer while keeping their material safe and secure. Traditionally the only option available was rigid packaging such as bottles, cans, or pails.

To help you decide between flexible packaging or rigid packaging, let's discuss the advantages and disadvantages associated with each of them.

Advantages Of Flexible Packaging

• Lightweight.
• Mono-layer packaging is environmentally friendly as they typically contribute to less landfill waste.
• More economical with less plastic and logistics cost.
• Greater shelf appeal due to ability to be 100% printed.

Disadvantages Of Flexible Packaging

• Exposure to extreme temperatures could affect the integrity of the package.
• More difficult to package with fewer co-packers who handle these containers.
• Limited shapes and package sizes due to rigidity constraints.
• Not as durable or chemical resistant as rigid packaging.
• Typically single use.

Advantages Of Rigid Packaging

• Extremely durable with a wide range of package sizes and chemical resistances.
• Easy to have packaged at many co-packer facilities with standard equipment.
• Protects your product from moisture, abrasion, and oxygen.

Disadvantages Of Rigid Packaging

• More expensive to make than flexible packages.
• Logistics and material handling requirements are significantly more for the same volume container.

Which Packaging Is More Economical?

Both pouches and bottles are made from materials like plastic. Unlike bottles, pouches only need a maximum of three layers (190 microns) of plastic, and can use as low as 50 microns.

Due to such a thin wall used for flexible packaging much less plastic is used to achieve the same volume container. They can also be shipped and stored flat packed to reduce space requirements and logistics costs.

As a result, pouch packaging is more economical than bottle packaging.

Which Packaging Is More Environmentally Friendly?

Pouches are more environmentally friendly than bottles due to the fact that they use less plastic. It is typically estimated that pouches reduce plastic use and carbon emissions from production by up to 80% vs traditional rigid packaging.

If multilayer pouches with non-compatible materials are used they may not be as recyclable as bottles. This is mostly seen with 3-ply pouches since they typically contain a non-recyclable barrier layer sandwiched between the recyclable materials.

However, once pouches are emptied they will be flat and take up less space in landfills than bottles.

Choosing Between Flexible Or Rigid Packaging?

Flexible packaging is becoming more common in many markets as consumers and companies become more conscious of the environmental impacts of their packaging choice. However, there will always be products that just cannot be packaged in a pouch and that is where rigid packaging comes in.

Take the time to decide on which packaging is best for your product by examining the cost, environmental effects, and durability.

For clarification, examine the boxes in the chart below as you go about your decision process.

Considerations

Flexible Packaging

Rigid Packaging

Cost

Low

Medium

Shipping & Storage Cost

Low

High

Carbon Dioxide Emission

Low

High

Recyclability

Depends

High

Product-to-Packaging Ratio

High

Low

Marketing/Shelf Impact

High

Medium

Shelf Life

Medium

High

Chemical Resistance

Medium

High

Durability

Medium

High