FLEXIBLE PACKAGING SOLUTIONS
We design flexible packaging structures for sweet and savory cookies and crackers, combining high-speed BOPP laminates, airtight sealing, and sustainable options tailored to each product type.
Ultra-lightweight BOPP laminates for high-speed production lines.
Airtight seal to preserve crispness throughout the shelf life.
BOPP secondary packaging for bulk packages and assortment boxes.
Technical support from the specification phase through production.
Cookies have two requirements that define their packaging specifications: high packaging speed, because they are produced on extremely high-productivity lines where the packaging material must be compatible without causing stoppages, and the preservation of crispness, because loss of texture is the primary quality indicator that consumers evaluate at the time of consumption.
Litoplas works with cookie manufacturers in Colombia and Central America, developing high-speed, lightweight BOPP packaging structures that maintain line productivity while preserving the product’s organoleptic properties.
The cookies are packaged on very high-speed flow-pack lines. The material must have a stable sealing temperature, mechanical tear resistance, and a precise roll width to prevent stoppages or rejects due to misalignment.
The crispness of a cookie depends directly on the packaging maintaining an airtight seal throughout its shelf life. A poor seal allows moisture to enter, causing the cookie to become soft before the consumer opens the package. The material’s WVTR barrier also plays a role, especially in markets with high ambient humidity.
For high-turnover cookies, the per-unit packaging cost is a critical factor. Ultra-lightweight BOPP laminates allow for higher yield per roll with less material weight, reducing packaging costs without compromising sealing properties or mechanical strength.
Cookies compete on store shelves against a high density of products. The sharpness of the print and the color accuracy of the packaging are key factors in visual differentiation at the point of sale.
The primary packaging for cookies must be compatible with the high-speed flow-pack packaging line and ensure an airtight seal to preserve crispness.
– Ultra-lightweight, high-speed BOPP laminates for high-productivity packaging lines.
– High-integrity hermetic sealing to prevent moisture ingress throughout the product’s shelf life.
– High-resolution printing for brand communication at the point of sale.
Crackers have requirements similar to those of conventional cookies but are more sensitive to moisture due to their more porous structure and lower fat content.
– BOPP laminates with an optimized moisture barrier for crackers and high-porosity whole-grain cookies.
– Compatibility with high-speed horizontal flow-pack lines for single-serve and multipack formats.
Secondary packaging groups several units together in a shelf display or for the institutional channel, with requirements for mechanical strength to withstand stacking and product visibility.
– BOPP film for manual or automatic packaging in multipacks and assortment boxes.
– High-integrity hermetic seal to prevent moisture ingress throughout the product’s shelf life.
– Options with a transparent window for product visibility in premium packaging.
We develop flexible packaging solutions for snacks that incorporate sustainable alternatives such as recyclable materials, single-material structures, and materials reclaimed through mechanical and chemical processes, tailored to the technical requirements of each product.
These solutions aim to maintain the packaging’s performance while preserving properties such as protection, strength, and barrier properties that are essential for this product category.
Ultra-lightweight BOPP — less material per unitUltra-lightweight BOPP laminates reduce the weight of the material per packaged unit without compromising sealing properties or mechanical strength, thereby lowering plastic consumption per box of cookies produced.
Single-material packaging with Plaxi HBFor cookies with medium barrier requirements, single-material PE structures with Plaxi HB are compatible with conventional mechanical recycling streams, enabling progress toward a circular economy without compromising the product’s crispness.
A loss of crispness is generally related to airtightness issues in the packaging seal, which allows moisture to enter. Reviewing the sealing process—temperature, pressure, and speed—along with evaluating the material’s WVTR usually identifies the source of the problem.
The primary packaging is the layer in direct contact with the product; it is made of high-speed BOPP for the flow-pack line. The secondary packaging groups several units together into a package for supermarket shelves or institutional channels, with a greater emphasis on mechanical strength for stacking than on barrier properties.
Plaxi technology is a proprietary optimization developed by Litoplas and applied to BOPP structures, which simultaneously improves the material’s body, optical properties, and moisture barrier properties.
In many cases, yes, especially on VFFS lines where the only adjustment required is the sealing temperature. For flowpack and wickett processes, a preliminary technical evaluation is essential.
Please fill out our form, indicating your industry, product type, estimated volume, and any special requirements. Our technical and sales team will contact you as soon as possible.
Tell us about your project, and our team will help you find the right solution.
