As the supplement industry evolves, packaging plays an increasingly important role in product presentation, shelf life, and sustainability. One of the most common packaging formats today is the pouch - often marketed as an eco-friendly alternative to plastic bottles.  


While pouches do offer certain advantages, they are not necessarily a superior choice for the environment or product integrity. In this article, we will explore the advantages and disadvantages of using pouches for food supplements and key considerations for biodegradable or plastic-free packaging.  


Pros of Using Pouches for Food Supplements


1. Reduced Material Usage

Compared to rigid plastic or glass bottles, flexible pouches use significantly less material. This can result in lower transportation costs and a reduced carbon footprint due to their lighter weight and smaller volume.  


2. Potentially Lower Unit Costs

Flexible packaging often requires fewer raw materials and may be cheaper to manufacture than plastic or glass bottles, making it a cost-effective choice for supplement brands. However, this has to be weighted against potential MOQ issues which we will discuss later.


3. Aesthetically Pleasing and Marketable

Many brands prefer pouches because they offer a sleek, modern, and premium look. They allow for:

  • Full-surface branding – Unlike bottles that require labels, pouches can be fully printed with eye-catching designs.
  • Premium finishes – Matte, soft-touch, or metallic finishes create a high-end feel.
  • Flexible shapes and sizes – Giving brands more creative control over visual identity.

Consumers often perceive well-designed pouches as stylish, eco-conscious, and innovative, making them an attractive choice for marketing.


Cons of Using Pouches for Food Supplements


1. High Minimum Order Quantities for Pre-Printed Pouches

For brands that want custom-branded pouches with pre-printed designs (instead of applying labels), a significant challenge is the minimum order quantity (MOQ).  


Many manufacturers require brands to order at least 2,000 pre-printed pouches per product to make production financially viable. This can be a problem for:  

- Smaller businesses or startups that don’t want to commit to large stock volumes.  

- Brands with multiple products or variations, as they would need to print high volumes for each SKU.  

- Product changes and reformulations, where brands may be stuck with thousands of obsolete pouches if they modify an ingredient or regulatory requirement.  


This often forces brands to either:  

✔ Use generic pouches with labels (which can look less professional).  

✔ Take financial risks by over-ordering pouches that may not be used in time.  


2. Recycling Challenges

Most pouches are made from multi-layered materials (plastic, aluminum, or biodegradable films) to provide adequate barrier protection. However, these composite structures are difficult to recycle in standard waste streams, meaning many pouches end up in landfills or incinerators.  


3. Misconceptions About Sustainability

Many consumers assume that because pouches use less plastic than bottles, they are automatically a better choice for the environment. However, most flexible packaging is:  

❌ Difficult to recycle due to its multi-layer composition.  

❌ Rarely biodegradable, unless specially formulated (which has its own challenges).  

❌ Not compostable at home, even if labeled as "biodegradable" (which often requires industrial composting).  


Thus, without an effective end-of-life disposal strategy, pouches may not be as eco-friendly as they seem.  


4. Shelf Life and Product Integrity Issues 

Food supplements require protection from moisture, light, and oxygen to maintain their potency over 2-3 years.  


Traditional pouches made with plastic-aluminum laminates provide excellent protection, but switching to biodegradable or plastic-free alternatives introduces challenges:  

  • Barrier Limitations: Many biodegradable films do not provide the same level of moisture and oxygen resistance, leading to product degradation.  
  • Structural Integrity: Some plant-based materials may become brittle or lose their seal over time, increasing the risk of contamination.  
  • Exposure to Light and Air: Without high-quality barrier layers, sensitive ingredients (e.g., probiotics, vitamins, or herbal extracts) may degrade before the expiration date.  


5. Consumer Perception and Practicality

While pouches are marketed as an eco-friendly innovation, some consumers find them:  

  • Less premium than bottles or glass jars.  
  • Harder to handle, especially for powder supplements prone to spillage.  
  • Inconvenient -  if resealing mechanisms fail over time.  


For brands in the high-end supplement market, pouches may not always align with consumer expectations for premium packaging.  


Considerations for Biodegradable or Plastic-Free Pouches


1. Ensuring Long-Term Shelf Stability  

Most supplements have a shelf life of 2-3 years, so biodegradable alternatives must offer equal or better barrier protection against air, moisture, and light.  


Some emerging materials include:  

  • PLA (Polylactic Acid) – A compostable option, but not moisture-resistant unless coated.  
  • Cellulose-Based Films – Biodegradable, but require coatings to prevent oxygen exposure.  
  • Paper-Based Pouches with Barrier Linings – Need biodegradable linings, which can still make recycling complicated.  


2. Real-World Testing for Stability

Switching to biodegradable materials requires extensive testing, including:  

✔ Heat and humidity resistance tests to ensure packaging does not degrade prematurely.  

✔ Seal integrity tests to prevent leakage over time.  

✔ Light exposure assessments to prevent oxidation of sensitive ingredients.  


3. Proper Disposal and End-of-Life Considerations

A sustainable pouch should be either compostable or recyclable, but most biodegradable plastics require industrial composting, which is not widely accessible.  


Brands should provide clear disposal instructions so consumers know whether to:  

- Recycle it in specialty recycling programs.  

- Compost it (if home-compostable).  

- Dispose of it in general waste (if unavoidable).  


4. Educating Consumers on Eco-Friendly Packaging  

Even if a pouch is biodegradable, consumers may not dispose of it correctly. Clear instructions on how and where to recycle or compost the packaging can prevent contamination of waste streams.  


Conclusion: Are Pouches the Right Choice?


While pouches offer some advantages, they come with significant considerations, including:  

  • Difficult recycling & environmental concerns 
  • Barrier limitations for long-term supplement stability
  • High minimum order quantities (MOQs) for pre-printed designs


For brands considering biodegradable or plastic-free alternatives, it’s essential to:  

✔ Conduct shelf life and stability testing to prevent product degradation.  

✔ Select materials with adequate oxygen, moisture, and light barriers.  

✔ Provide clear disposal instructions to consumers.  

✔ Weigh cost implications of high MOQs for custom-printed pouches.  


Until fully sustainable solutions become widely available, brands must balance practicality with sustainability to ensure their packaging aligns with both environmental responsibility and product integrity.  


For brands eager to demonstrate their commitment to the environment, it might be worth considering an affiliation with a green scheme such as GreenSpark which will allow your business to impact the environment in a positive manner through love global projects.