Whole Foods Market had a problem. The multi-layer paper bags with BOPP sealant layer weren’t providing enough of a barrier to its tortilla chip packaging from oxygen and moisture. As a result, the chips were turning soggy and rancid prematurely. This, among other paper-related issues, compelled Whole Foods to search for an alternative packaging solution – which is where Uflex enters the picture.

Whole Foods did not want to create any confusion in the minds of consumers regarding the look and appeal of its tortilla chips packaging. Moreover being the largest seller of organic food in the U.S., Whole Foods wanted to create a paper-like organic look to the packaging.

The engineers at Uflex designed a three-layered 12.5-micron coated polyester, 18-micron BOPP and 35-micron polyethylene packaging structure as a 3D flat-bottom pouch. Polyester provides excellent barrier from oxygen and also exhibits good thermal resistance due to its high melting temperature. PE serves as a sealant layer and adds strength and sturdiness to the pouch. To impart a paper-like organic look, special registered matte coating was applied on the glossy polyester film.

The pouch is reverse printed features a transparent window. A concealed press-to-close (PTC) pocket zipper has been provided on the front panel of the 3D pouch with a perforated strip for easy opening and protection. It’s worth noting that usually pouches have to be cut from the top using scissors or knives in order to retrieve the snack, which can lead to contamination. The PTC slider pocket pouch eliminates this shortcoming.

The transformed packaging offers the following advantages:

  • Increased shelf life from about three weeks to three months.
  • Convenience.
  • A 360-degree branding canvas.

What’s more is the revamped packaging did not require any new or specialized filling and sealing.