{"id":154196,"date":"2026-10-08T16:22:12","date_gmt":"2026-10-08T14:22:12","guid":{"rendered":"https:\/\/encanto.it\/uncategorized\/barrier-packaging-for-dietary-supplements\/"},"modified":"2026-10-08T21:53:47","modified_gmt":"2026-10-08T19:53:47","slug":"barrier-packaging-for-dietary-supplements","status":"publish","type":"post","link":"https:\/\/encanto.it\/en\/magazine\/barrier-packaging-for-dietary-supplements\/","title":{"rendered":"Barrier Packaging: what actually protects a dietary supplement"},"content":{"rendered":"

[vc_row row_height_percent=”0″ override_padding=”yes” h_padding=”4″ top_padding=”3″ bottom_padding=”3″ overlay_alpha=”50″ gutter_size=”3″ column_width_percent=”100″ shift_y=”0″ z_index=”0″ content_parallax=”0″ uncode_shortcode_id=”140645″][vc_column column_width_percent=”100″ gutter_size=”3″ overlay_alpha=”50″ shift_x=”0″ shift_y=”0″ shift_y_down=”0″ z_index=”0″ medium_width=”0″ mobile_width=”0″ css_animation=”alpha-anim” animation_delay=”200″ width=”1\/1″ uncode_shortcode_id=”168838″][vc_custom_heading text_color=”accent” heading_semantic=”h1″ text_font=”font-805350″ text_size=”fontsize-575479″ uncode_shortcode_id=”193938″ text_color_type=”uncode-palette”]Barrier Packaging: what actually protects a dietary supplement[\/vc_custom_heading][vc_column_text uncode_shortcode_id=”938493″]<\/p>\n

Packaging seems like the final decision for a product: the formula is ready, the format has been chosen \u2014 all that\u2019s left is \u201cthe packaging.\u201d In reality, package is a technical specification in every sense of the word, and it performs a task that isn\u2019t immediately visible: determining whether the active ingredient you\u2019ve included in the formula remains intact until the end of its shelf life, or whether some of it is lost along the way.<\/h2>\n

Because a supplement doesn\u2019t just age on the shelf. It ages in interaction with its environment through its packaging, and three factors in particular work against its contents: oxygen, light, and moisture. Each group of ingredients is particularly vulnerable to one of these three.<\/h2>\n

[\/vc_column_text][\/vc_column][\/vc_row][vc_row row_height_percent=”0″ override_padding=”yes” h_padding=”0″ top_padding=”0″ bottom_padding=”3″ overlay_alpha=”50″ gutter_size=”0″ column_width_percent=”100″ shift_y=”0″ z_index=”0″ mobile_visibility=”yes” content_parallax=”0″ uncode_shortcode_id=”164114″][vc_column column_width_percent=”100″ align_horizontal=”align_center” gutter_size=”0″ override_padding=”yes” column_padding=”0″ overlay_alpha=”50″ shift_x=”0″ shift_y=”0″ shift_y_down=”0″ z_index=”0″ medium_width=”0″ mobile_width=”0″ css_animation=”alpha-anim” animation_delay=”200″ width=”1\/1″ uncode_shortcode_id=”157773″][vc_single_image media=”154197″ caption=”yes” media_width_percent=”100″ alignment=”center” shape=”img-round” radius=”hg” css_animation=”alpha-anim” uncode_shortcode_id=”134816″ media_link=”url:https%3A%2F%2Fencanto.it%2Fen%2Fdoypack-2%2F|title:Doypack|”][\/vc_column][\/vc_row][vc_row row_height_percent=”0″ override_padding=”yes” h_padding=”0″ top_padding=”0″ bottom_padding=”3″ overlay_alpha=”50″ gutter_size=”0″ column_width_percent=”100″ shift_y=”0″ z_index=”0″ desktop_visibility=”yes” medium_visibility=”yes” content_parallax=”0″ uncode_shortcode_id=”136550″][vc_column column_width_percent=”100″ align_horizontal=”align_center” gutter_size=”0″ override_padding=”yes” column_padding=”0″ overlay_alpha=”50″ shift_x=”0″ shift_y=”0″ shift_y_down=”0″ z_index=”0″ medium_width=”0″ mobile_width=”0″ css_animation=”alpha-anim” animation_delay=”200″ width=”1\/1″ uncode_shortcode_id=”776061″][vc_single_image media=”154198″ caption=”yes” media_width_percent=”100″ media_ratio=”nine-sixteen” alignment=”center” shape=”img-round” radius=”hg” advanced=”yes” media_items=”media|original” media_overlay_opacity=”1″ media_h_align=”center” media_h_position=”center” media_padding=”2″ css_animation=”alpha-anim” uncode_shortcode_id=”130401″ media_link=”url:https%3A%2F%2Fencanto.it%2Fen%2Fco-packing%2F|title:Co-Packing|” media_caption_custom=”Gli Adattogeni non contrastano lo stress \u2014 lo attraversano.”][\/vc_column][\/vc_row][vc_row row_height_percent=”0″ override_padding=”yes” h_padding=”4″ top_padding=”0″ bottom_padding=”2″ overlay_alpha=”50″ gutter_size=”3″ column_width_percent=”100″ shift_y=”0″ z_index=”0″ content_parallax=”0″ uncode_shortcode_id=”660358″][vc_column column_width_percent=”100″ gutter_size=”3″ overlay_alpha=”50″ shift_x=”0″ shift_y=”0″ shift_y_down=”0″ z_index=”0″ medium_width=”0″ mobile_width=”0″ css_animation=”alpha-anim” animation_delay=”200″ width=”1\/1″ uncode_shortcode_id=”168838″][vc_column_text uncode_shortcode_id=”695235″]<\/p>\n

Oxygen: oxidation<\/h2>\n

It is the enemy of ingredients that oxidize upon contact with air. Omega-3s become rancid, affecting the product\u2019s smell, taste, and nutritional value. Vitamin C degrades. The same is true for many oils, Polyphenols, and Antioxidant compounds, which, by definition, react with oxygen. Here, the material\u2019s barrier properties are measured by a specific index, the OTR \u2014 the amount of oxygen that passes through the film per unit of time: the lower the OTR, the better the packaging protects the contents.<\/p>\n

Light: photodegradation<\/h2>\n

Some active ingredients degrade when exposed to light, particularly to ultraviolet radiation. This applies to Carotenoids and Lutein, Vitamin A, Riboflavin, and even Melatonin, which is photosensitive. A transparent container allows light to pass through completely: while this choice enhances the product\u2019s appearance on the shelf, it comes at the cost of stability for light-sensitive active ingredients. An opaque material, amber glass, or a film with a light-blocking layer can make all the difference here.<\/p>\n

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Transparent packaging is often a marketing choice. For a light-sensitive product, this can cost it points in the ratings at the end of its shelf life: the product on the label is no longer the same as the one in the bag.<\/h2>\n<\/blockquote>\n

Humidity: the role of water<\/h2>\n

Moisture that enters the package triggers reactions, causes powders to clump, and leads to a loss of efficacy. This is a critical factor for Probiotics and Postbiotics \u2014 where the viability of the strains is key \u2014 as well as for Hygroscopic Powders, Effervescent Tablets, and Chewable forms. Here, too, there is an index \u2014 the WVTR \u2014 that measures how much water vapor passes through the material. And here, too, the container does not work alone: the cap, the seal, and any desiccant packet are all part of the barrier system.<\/p>\n

[\/vc_column_text][vc_row_inner row_inner_height_percent=”0″ force_width_grid=”yes” overlay_alpha=”50″ gutter_size=”0″ shift_y=”0″ z_index=”0″ mobile_visibility=”yes” uncode_shortcode_id=”972495″][vc_column_inner column_width_percent=”100″ align_horizontal=”align_center” gutter_size=”0″ overlay_alpha=”50″ shift_x=”0″ shift_y=”0″ shift_y_down=”0″ z_index=”0″ medium_width=”0″ mobile_width=”0″ width=”1\/1″ uncode_shortcode_id=”202287″][vc_single_image media=”154199″ media_width_percent=”100″ alignment=”center” shape=”img-round” radius=”hg” css_animation=”alpha-anim” uncode_shortcode_id=”186683″ media_link=”url:https%3A%2F%2Fencanto.it%2Fen%2Fpackaging%2F|title:Packaging|”][vc_empty_space empty_h=”2″][vc_column_text uncode_shortcode_id=”101590″]Sachets, Stick Packs, Doypacks (plastic- or paper-based), and Blister packs: the multilayer structure of each format, with Aluminum as one of the layers.[\/vc_column_text][\/vc_column_inner][\/vc_row_inner][vc_row_inner row_inner_height_percent=”0″ force_width_grid=”yes” overlay_alpha=”50″ gutter_size=”0″ shift_y=”-2″ z_index=”0″ desktop_visibility=”yes” medium_visibility=”yes” uncode_shortcode_id=”286567″][vc_column_inner column_width_percent=”100″ align_horizontal=”align_center” gutter_size=”0″ overlay_alpha=”50″ shift_x=”0″ shift_y=”0″ shift_y_down=”0″ z_index=”0″ medium_width=”0″ mobile_width=”0″ width=”1\/1″ uncode_shortcode_id=”670389″][vc_single_image media=”154200″ media_width_percent=”100″ alignment=”center” shape=”img-round” radius=”hg” css_animation=”alpha-anim” uncode_shortcode_id=”577542″ media_link=”url:https%3A%2F%2Fencanto.it%2Fen%2Fpackaging%2F|title:Packaging%20Formats|”][vc_empty_space empty_h=”2″ desktop_visibility=”yes” medium_visibility=”yes”][vc_column_text uncode_shortcode_id=”629953″]Sachets, Stick Packs, Doypacks (plastic- or paper-based), and Blister packs: the multilayer structure of each format, with Aluminum as one of the layers.[\/vc_column_text][\/vc_column_inner][\/vc_row_inner][vc_row_inner row_inner_height_percent=”0″ overlay_alpha=”50″ gutter_size=”3″ shift_y=”0″ z_index=”0″ desktop_visibility=”yes” medium_visibility=”yes” mobile_visibility=”yes” uncode_shortcode_id=”382628″][vc_column_inner column_width_percent=”100″ align_horizontal=”align_center” gutter_size=”3″ override_padding=”yes” column_padding=”0″ overlay_alpha=”50″ shift_x=”0″ shift_y=”0″ shift_y_down=”0″ z_index=”0″ medium_width=”0″ mobile_width=”0″ width=”1\/1″ uncode_shortcode_id=”759323″][vc_custom_heading text_color=”accent” heading_semantic=”h6″ text_size=”h6″ text_transform=”uppercase” uncode_shortcode_id=”273516″ text_color_type=”uncode-palette”]WANT KNOW MORE?[\/vc_custom_heading][vc_custom_heading heading_semantic=”h3″ text_size=”custom” uncode_shortcode_id=”206028″ heading_custom_size=”46px”]From Formula to Form and Typologies[\/vc_custom_heading][vc_button button_color=”accent” size=”btn-sm” border_width=”0″ link=”url:https%3A%2F%2Fencanto.it%2Fen%2Ftypologies%2F|title:Forms%20and%20Typologies|” button_color_type=”uncode-palette” uncode_shortcode_id=”161158″]Read more[\/vc_button][\/vc_column_inner][\/vc_row_inner][vc_column_text uncode_shortcode_id=”185239″]<\/p>\n

Materials, from the most protective to the most permeable<\/h2>\n

Aluminum provides a complete barrier: it blocks oxygen, light, and moisture all at once. That\u2019s why Stick Packs<\/a>, Doypack<\/a>, and multilayer Pouche<\/a> with aluminum foil \u2014 or ALU-ALU Blisters<\/a> \u2014 are the formats that best protect sensitive active ingredients. When aluminum is not present \u2014 such as with a transparent film or a single-material plastic \u2014 the barrier performance decreases, and it must be verified that the active ingredient can still withstand this throughout the product\u2019s shelf life.<\/p>\n

However, the barrier is not the only criterion. The same aluminum-laminated multilayer film that provides the best protection is also the most difficult to recycle, because it combines different materials that must be separated at the end of its life. This is precisely the point emphasized by the new recyclability requirements: you can find an overview in our article on PPWR and Green Claims<\/a>. Asset protection and material recyclability are two requirements that pull in opposite directions, and the right formulation lies at the point where they meet.<\/p>\n

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Sachets<\/h2>\n

Structure:<\/strong> PET-ALU-PE multilayer
\nBarrier:<\/strong> total \u2014 aluminum blocks oxygen, light, and moisture
\nDisposal:<\/strong> plastic recycling<\/p>\n

Stick Packs<\/h2>\n

Structure:<\/strong> PET-ALU-PE multilayer
\nBarrier:<\/strong> total
\nDisposal:<\/strong> plastic recycling<\/p>\n

Doypack plastic-based<\/h2>\n

Structure:<\/strong> PET-ALU-PE multilayer (or PET-ALU-PET-PE, with reinforcing PET)
\nBarrier:<\/strong> total
\nFormat:<\/strong> stand-up, with or without a straw
\nDisposal:<\/strong> plastic recycling<\/p>\n

Doypack paper based<\/h2>\n

Structure:<\/strong> FSC\u00ae<\/sup>-ALU-PE paper (or Paper-ALU-PET-PE)
\nBarrier: <\/strong>total \u2014 aluminum serves as the barrier layer, while paper is the outer layer
\nDisposal: <\/strong>paper recycling (paper constitutes the majority by weight)<\/p>\n

Blister<\/h2>\n

Structure:<\/strong> PVC-ALU (PVC also available in PCR version, post-consumer recycled) or ALU-ALU (cold-formed)
\nBarrier:<\/strong> medium with PVC-ALU (the PVC cell acts as the barrier) \u00b7 total with ALU-ALU
\nDisposal:<\/strong> plastic recycling<\/p>\n

In all formats, the presence of aluminum distinguishes waste disposal from material recycling: \u201cDisposable\u201d does not mean \u201cRecyclable.\u201d<\/em><\/p>\n

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The format is part of the barrier<\/h2>\n

The same formula, when packaged differently, has a different shelf life. A single-dose packet sealed in aluminum isolates each individual dose from the environment until the moment of use; a bottle, on the other hand, exposes the contents every time it is opened, and this must be compensated for with proper sealing, filling, and sometimes a protective atmosphere. Choosing between a stick pack, Doypack, Blister pack, or bottle isn\u2019t just a matter of convenience and shelf appeal\u2014it\u2019s a choice that determines the product\u2019s barrier profile.<\/p>\n

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The barrier determines the maturity value at the end of the term, not at the time of packaging. An asset that is compliant at the outset but is not protected may no longer be protected by the stated maturity date.<\/h2>\n<\/blockquote>\n

This is an aspect directly linked to Bioavailability<\/a> and dosage: it\u2019s not just about how much active ingredient you include in the formula, but how much of it remains active when the product is taken. The same reasoning applies to ingredients that are most exposed to oxidative stress, where the packaging is just as much a part of the protection strategy as the formula itself.<\/p>\n

A decision to be made in advance<\/h2>\n

The barrier cannot be corrected downstream, on a product that has already been defined. It is established during the development phase, along with the active ingredient and the format: we start by identifying what the ingredient is sensitive to \u2014 oxygen, light, or moisture \u2014 and from there, we determine the material and structure that will protect it throughout its shelf life, verifying the suppliers\u2019 data on materials in contact with the product. Designing the packaging after finalizing the formula often means realizing too late that the formula actually required a different barrier.<\/p>\n

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If you’re developing a product and want to choose the material and format based on what the product needs to withstand, talk to us<\/a>.<\/h2>\n<\/blockquote>\n

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Oxygen, light, and moisture degrade active ingredients before their expiration date. How materials and packaging act as barriers, and the issue of recyclability.<\/p>\n","protected":false},"author":18,"featured_media":154197,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[180],"tags":[598,607,641,868],"class_list":["post-154196","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-magazine","tag-co-packing","tag-sustainability","tag-food-packaging","tag-supplement-packaging"],"_links":{"self":[{"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/posts\/154196","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/users\/18"}],"replies":[{"embeddable":true,"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/comments?post=154196"}],"version-history":[{"count":5,"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/posts\/154196\/revisions"}],"predecessor-version":[{"id":154236,"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/posts\/154196\/revisions\/154236"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/media\/154197"}],"wp:attachment":[{"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/media?parent=154196"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/categories?post=154196"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/encanto.it\/en\/wp-json\/wp\/v2\/tags?post=154196"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}