Selecting a packaging technology is a sequence of trade-offs, not a single decision.
1. Start with the product
Its state, shelf-life target and sensitivity to oxygen and moisture set the barrier requirement before anything else.
2. Define the format
Blister, tray, pouch, skin pack or flow wrap — driven by how the product is presented, dispensed and opened.
3. Match the barrier and material
OTR and WVTR targets decide whether you need a high-barrier laminate, foil, or a mono-material.
4. Size the line
Throughput, changeover and automation level decide between manual, semi-automatic and fully automated FFS systems.
5. Layer in regulation
Medical and pharma products add ISO 11607, EU MDR and validation requirements that constrain choices from the outset.
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Five common mistakes in sterile barrier packaging