Barrier testing
Table of Contents
How do we confirm the barrier properties of flexible packaging without aluminium and EVOH?
Growing requirements related to recycling and packaging design in line with “design for recycling” principles mean that more and more companies are looking for alternatives to classic barrier structures based on aluminium, metallisation, or EVOH. However, one key question arises: how can you confirm that a new, simplified package actually protects the product?
At Mardruk Packaging, we answer this through barrier testing. One of the most important parameters we analyse is OTR, or Oxygen Transmission Rate.
What is OTR?
OTR, or Oxygen Transmission Rate, determines the amount of oxygen that passes through a defined surface area of material within a specified time and under specific test conditions. This parameter is most commonly expressed in cm³/m²/24 h.
The lower the OTR value, the better the oxygen barrier of the packaging.
For many food products, oxygen is one of the main factors affecting shelf life, taste, aroma, colour, and product stability. That is why, in the case of oxygen-sensitive products, we do not rely solely on declarations. We verify the parameters through testing.
MOCON measurement - objective confirmation of barrier performance
To assess oxygen permeability, we use a MOCON device. It allows us to precisely determine how much oxygen passes through the tested structure within a specific period of time.
This measurement allows us to:
- precisely assess oxygen permeability,
- compare barrier coating with classic solutions,
- make technological decisions based on data, not assumptions.
As a result, the customer can assess whether a given structure is sufficient for their product before implementing it in serial production.
Barrier coating as an alternative to aluminium and EVOH
For years, high barrier performance has been achieved through the use of aluminium, metallised layers, EVOH, AlOx, or SiOx. These are effective solutions, but they often increase packaging complexity and may make recycling more difficult.
That is why we are developing solutions based on barrier coating. They make it possible to design modern flexible packaging in a more simplified way, without the need to use classic multilayer barrier structures.
What does low OTR mean in practice?
A low OTR value is directly important for products sensitive to oxygen. In practice, it means better protection of aroma, taste, colour, and product properties throughout its shelf life.
For the manufacturer, this means greater control over product quality and a lower risk of problems caused by insufficient packaging barrier performance.
Barrier coating can support the packaging of products such as coffee, snacks, loose products, fatty products, dry products, and other goods for which quality stability over time is crucial.
How do we compare different structures?
If a customer is considering changing their current packaging to a structure without aluminium or EVOH, we start with an analysis and comparison of parameters.
We can compare the currently used packaging with a structure based on aluminium, EVOH, metallisation, or a solution with barrier coating. The key reference point is the OTR test result.
This allows the customer to see whether the alternative solution meets the requirements of their product. It reduces implementation risk and makes it possible to make decisions based on data.
Summary
At Mardruk, barrier packaging is treated as an integral element of product protection, not merely as a carrier for graphics. Thanks to the work of the R&D team and the use of modern laboratory equipment, we develop solutions that:
- provide real protection for the contents,
- extend product shelf life,
- meet growing regulatory requirements,
- remain stable and predictable in serial production.
Contact our technology team and send us your specification – we will prepare a recommendation for the material and process configuration.
- Order a free consultation and specification covering the substrate, activation and perforation.
- Order samples and a pilot production run.
- Receive a fast quotation and a delivery plan that stays on schedule.
Write to us or call – we will respond quickly and precisely.
FAQ
MOCON is a specialist device used to test gas permeability through packaging materials. In the case of barrier packaging, it allows oxygen permeability to be measured precisely and different material structures to be compared.
In many applications, barrier coating can be an alternative to classic structures with aluminium, metallisation, AlOx, SiOx, or EVOH. However, the final choice of solution should depend on the product requirements, expected shelf life, and OTR test results.
An OTR test is worth performing when changing the packaging structure, eliminating aluminium, EVOH, or metallisation, implementing packaging designed for recycling, comparing several materials, and for products that are particularly sensitive to oxygen.
