What brands should expect from a flex packaging company in 2026
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Short answer for packaging teams
A flex packaging company in 2026 should be judged on more than print quality, pouch appearance or unit price. Brand teams need evidence that a converter or material partner can meet the required barrier performance, food-contact or product-safety requirements, machinability, shelf impact, regulatory documentation and end-of-life claims. The best supplier discussions start with a precise brief: product sensitivity, filling process, distribution conditions, target market, shelf-life goals, artwork needs, and the sustainability claims the brand wants to make. For a broader packaging context, see our flexible packaging category.
The commercial reason is straightforward. Flexible packaging remains a large and important market, while rules around recyclability, recycled content, extended producer responsibility and environmental claims are becoming more specific. According to the Flexible Packaging Association, the U.S. flexible packaging industry reached $42.6 billion in annual sales in 2024, up from $41.4 billion in 2023. At that scale, supplier selection is a strategic decision, not just a purchasing task. (flexpack.org)
Why the supplier brief is changing
Flexible formats such as pouches, films, sachets, wraps, lidding and rollstock are widely used because they can reduce material weight, protect products and run on high-speed packing lines. The Flexible Packaging Association notes that flexible films can help reduce food loss and that a flexible pouch may require up to 60% less plastic than an equivalent rigid container, depending on the application and comparison basis. These advantages matter most when protection, portion control and distribution efficiency help prevent waste. (flexpack.org)
End-of-life recovery is still the more difficult part of the equation. The U.S. Environmental Protection Agency’s latest national municipal solid waste tables are based on 2018 data. For plastic containers and packaging, the EPA reported that 16.9% was combusted with energy recovery, while more than 69% was landfilled. Flexible plastic films can also be difficult for curbside systems because they may wrap around sorting equipment or lack stable end markets. (epa.gov)
Regulation is also shifting from broad sustainability language to measurable obligations. In the European Union, the Packaging and Packaging Waste Regulation entered into force on February 11, 2025 and aims to make packaging fully recyclable by 2030 while reducing packaging waste per person by 2040 compared with 2018 levels. For companies selling into Europe, packaging design choices made now can affect future market access. (echa.europa.eu)
In the United States, extended producer responsibility for packaging is increasingly relevant. As of October 2026, seven states have enacted packaging EPR laws: Maine, Oregon, Colorado, California, Minnesota, Maryland and Washington. Circular Action Alliance states that it has been selected as the single producer responsibility organization in California, Colorado, Maryland, Minnesota, Oregon and Washington, while state programs still differ in definitions, exemptions, reporting and fee timing. (kcma.org)
What a capable flex packaging company should document
Fit-for-purpose material structure
A supplier should be able to explain why a structure fits the product, not simply provide a film name. The discussion should cover oxygen transmission, moisture vapor transmission, grease resistance, aroma retention, puncture resistance, sealant choice, hot-fill or cold-fill compatibility, freezer or retort exposure, and expected shelf life. For dry snacks, the priority may be moisture barrier and seal integrity. For coffee, aroma protection and degassing features may matter. For liquid or oily products, chemical compatibility and leak resistance become more important.
The key question is whether the proposed structure is the minimum structure that reliably protects the product through filling, shipping, retail display and use. A thinner or simplified film may look stronger in a sustainability scorecard, but it can create more waste if it fails during packing, distribution or storage.
Design for recycling and realistic end-of-life claims
Many brands are moving from mixed-material laminates toward mono-material polyethylene or polypropylene structures where performance allows. That direction can improve compatibility with film recycling pathways, but it is not automatically suitable for every product. High-barrier foods, medical products, aggressive chemicals and long distribution chains may still require more complex structures.
A responsible flex packaging company should separate design intent from actual access. The U.S. Federal Trade Commission’s Green Guides say marketers should qualify recyclable claims when recycling facilities are not available to at least 60% of the consumers or communities where the item is sold. In practice, a package can be technically designed for recycling and still require careful claim language if collection access is limited. (ftc.gov)
Compliance files and market-specific requirements
Packaging compliance is increasingly data-driven. Depending on the product type and sales geography, a brand may need food-contact documentation, material safety information, substance restrictions, certificates of analysis, migration testing support, recycled-content documentation, or EPR reporting data by material category and weight.
For U.S. EPR planning, Oregon shows why packaging data quality matters. The Oregon Department of Environmental Quality says covered producers must register with an approved producer responsibility organization, report covered product supply data and pay membership fees; Oregon’s approved PRO was allowed to begin charging fees from member producers on July 1, 2025. A brand that cannot separate packaging weights by material may struggle to report accurately. (oregon.gov)
California is another high-attention state. CalRecycle reported that it received Circular Action Alliance’s producer responsibility plan on October 13, 2026 and opened a public comment period through November 13, 2026. For brands selling nationally, a supplier’s ability to provide clean material data can be as important as the quoted rollstock price. (calrecycle.ca.gov)
Manufacturing quality and pack-line performance
Flexible packaging can fail in small but costly ways: weak seals, zipper misalignment, roll curl, ink rub, blocking, inconsistent coefficient of friction, poor machinability, pinholes or delamination. A competent supplier should define acceptable tolerances, inspection methods, change-control procedures and corrective action processes before production begins.
For new launches, sample evaluation should include trial runs on the actual filling equipment whenever possible. Lab performance is useful, but pack-line results show how the material handles speed, heat, pressure, product dust, contamination near the seal area and real operator conditions. See also: Box Design.
A practical evaluation framework
| Evaluation area | Evidence to request | Why it matters |
|---|---|---|
| Product protection | Barrier data, seal test method, drop or compression results where relevant | Prevents under-specification that leads to spoilage, leakage or returns |
| Material simplification | Comparison of current laminate versus mono-material or recyclable-ready alternatives | Shows whether sustainability improvements are technically realistic |
| Regulatory support | Food-contact statements, restricted-substance declarations and market-specific documentation | Reduces delays when selling across regions or product categories |
| EPR reporting | Material weights, resin types, components and packaging format data | Supports state-by-state reporting and fee calculations |
| Environmental claims | Claim review notes, access assumptions and supporting test data | Helps avoid overbroad recyclable, compostable or recycled-content claims |
| Production reliability | Specifications, tolerances, inspection records and change-control process | Protects pack-line uptime and repeat order consistency |
This framework helps purchasing, R&D, sustainability, legal and operations teams review the same evidence. It also prevents a common mistake: choosing the lowest-cost film before defining the performance, compliance and recovery requirements that determine total risk.
Where sustainability choices can create trade-offs
Material reduction is often the first sustainability lever because it lowers packaging weight without necessarily changing the pack format. However, downgauging has limits. If a thinner film increases punctures, seal failures or food waste, the apparent packaging reduction may not deliver a better overall outcome.
Mono-material flexible packaging is another important pathway, especially for store drop-off or future film recovery systems. The trade-off is that simplified structures may need new coatings, tie layers or processing adjustments to match the barrier and stiffness of conventional laminates. A supplier should be transparent about what has been tested and what still needs validation.
Paper-based flexible packaging can work for some dry products and can improve consumer perception, but it is not a universal replacement for plastic films. The Ellen MacArthur Foundation has noted that paper could be applicable for a portion of plastic flexibles, while compostable plastics may be relevant only where organic waste collection systems exist. The same organization emphasizes that flexibles require a mix of elimination, reuse, substitution and recycling strategies rather than a single solution. (ellenmacarthurfoundation.org)
Compostable flexible packaging also needs careful claim management. It should be considered where contamination with food scraps is likely and where the target market has access to appropriate composting infrastructure. Without that system, a compostable claim can create confusion rather than environmental benefit.
Post-consumer recycled content is increasingly important in regulation and brand commitments, but flexible food-contact applications can be constrained by availability, quality, odor, color, mechanical performance and authorization requirements. A reliable supplier should explain whether recycled content is mechanically recycled, chemically recycled under a mass-balance approach, or not suitable for the specific application. The answer should be documented, not assumed.
Questions to ask before requesting quotes
- Which product risks drove the recommended structure: oxygen, moisture, light, grease, aroma, puncture, chemical compatibility or heat exposure?
- Can the structure be simplified without reducing shelf life or pack-line efficiency?
- What testing supports the proposed barrier, seal strength and durability?
- Which components create recycling challenges, such as metallization, dark inks, adhesives, labels, valves, zippers or mixed polymers?
- What environmental claims can be supported in the intended sales markets?
- Can the supplier provide packaging weights and material categories for EPR reporting?
- How are specification changes communicated and approved?
- What happens if a resin, coating, adhesive or ink must be substituted?
- What minimum order quantity, lead time and artwork requirements apply?
- Will the supplier support line trials and failure analysis before full commercial launch?
The best supplier response is not always a quick yes. Packaging involves trade-offs, and an answer that identifies limits is often more useful than a broad promise. For regulated products, food-contact uses or environmental claims, brands should involve legal, regulatory and quality specialists before approving final artwork or market claims.
Frequently asked questions
What is a flex packaging company?
A flex packaging company typically converts or supplies flexible materials such as films, laminates, rollstock, pouches, sachets, wraps, lidding or bags. Some companies focus on printing and converting, while others provide materials, premade pouches, design support, testing or co-packing relationships.
Is flexible packaging always more sustainable than rigid packaging?
No. Flexible packaging can use less material and reduce transport weight, but sustainability depends on the full system: product protection, manufacturing losses, shelf life, consumer use, collection access and end-of-life options. A lightweight pouch that cannot be recovered may still be appropriate for some products if it prevents significant product waste, but the trade-off should be documented.
Should brands switch to mono-material flexible packaging?
Mono-material structures are worth evaluating when they can meet barrier, sealing and durability needs. They are not automatically suitable for every product. Brands should request side-by-side testing against the current structure and confirm whether the intended market has a realistic recovery pathway.
What information is needed for EPR reporting?
Requirements vary by state or country, but brands often need packaging format, material type, component weights, resin identification, recycled content, sales geography and producer role. Because state EPR programs differ, packaging teams should maintain data at a more detailed level than a simple total packaging weight.
How can a brand avoid weak environmental claims?
Claims should be specific, qualified and supported by evidence. Instead of saying a pouch is sustainable, a brand should identify the actual attribute, such as reduced material weight, recycled content percentage, design for a specific recycling stream, or verified compostability under defined conditions. Claim language should match the markets where the package is sold.
