Moisture and oxygen barrier
Dried fruit is hygroscopic. It absorbs moisture from the air, which makes pieces sticky, soft and prone to mould. The packaging must keep water vapour out. A film with a high moisture barrier is essential. PET/AL/PE and PET/NY/PE laminates are common choices. The aluminium layer in PET/AL/PE gives an excellent moisture barrier and also blocks light. PET/NY/PE offers good strength and a moderate moisture barrier without foil.
Oxygen also matters. Even though dried fruit has low water activity, residual oxygen can cause browning and flavour loss. For long shelf life, use a high-barrier structure and consider nitrogen flushing. If the product contains sulphites, choose a film that resists sulphur migration. Always test the full pack, not just the film, because seals and zippers can be weak points.
Pouch styles for dried fruit
The right bag shape depends on pack size, filling method and how the product will be displayed. Common options include:
Flat bottom pouch: stands well on shelf, good for 100 g to 1 kg. - Stand up pouch: popular for 50 g to 500 g, economical and widely used. - Flat or three-side-seal pouch: simple, low-cost, good for small samples or single-serve. - Side gusset bag: traditional look, often used for larger formats. - Spout pouch: for liquid or semi-liquid products, not typical for dried fruit. - Rollstock film: for high-speed form-fill-seal lines.
Add-ons can improve function and shelf appeal. A zipper makes the pack resealable, which is important for larger formats. A tear notch helps consumers open the bag without scissors. A window lets buyers see the product. A hang hole supports pegboard display. A one-way degassing valve is not needed for dried fruit, but is available for other products. Choose add-ons that match the filling line and the retail channel.
Filling and sealing considerations
Dried fruit is usually filled by weight. The pieces are irregular and can bridge in the hopper, so use a filler designed for sticky or irregular products. Volumetric fillers are common, but check that the target weight is achieved consistently. For small pieces, a multihead weigher gives better accuracy. If the product is dusted with sugar or flour, clean the seal area before sealing. Contamination in the seal can cause leaks.
Sealing is critical. The seal must be strong enough to survive distribution and handling. Test seal strength and burst pressure. For stand up pouches, the bottom seal is a common failure point. If the pack will be gas flushed, use a sealing machine that can handle the modified atmosphere. Always run a shelf-life test with the actual product and the final pack.
Cost drivers and order quantities
The main cost drivers are material structure, print method, order quantity and add-ons. A high-barrier foil laminate costs more than a standard PE film. Rotogravure printing has low unit costs at high volumes but requires plates, so it suits runs from 10,000 pouches or 200 kg of film. Digital printing has no plate cost, making it economical from 100 pouches or 10 kg of film. Flexographic printing sits between the two.
Add-ons increase cost. A zipper, spout, valve or window adds material and process steps. The more features, the higher the unit price. Order quantity also matters: larger runs spread setup costs over more units. Lead time depends on print method. Digital print runs typically take 10-15 working days after artwork approval. Rotogravure runs take 20-25 working days. Plan for both cost and time when choosing a structure.
Sustainability and material choices
Sustainability rules are changing. Some markets now require recyclable or compostable packaging. Mono-material PE and PP structures are recyclable where collection systems exist. They offer a good moisture barrier but may need a coating or EVOH layer to match the oxygen barrier of foil laminates. PLA/PBS compostable films are suitable for industrial composting, but they need specific storage and handling conditions. Degradable options are also available, but check local definitions.
Kraft paper laminates give a natural look and feel. They are often used for premium dried fruit. The paper layer provides stiffness and printability, while the inner layer provides the barrier. However, paper laminates may not be recyclable in all areas. Always confirm the local recycling or composting rules for the exact structure you choose. No single material is best for every market.
Common mistakes to avoid
Many buyers focus on the bag appearance and overlook the barrier. A beautiful pouch that lets in moisture will ruin the product. Another mistake is choosing a structure without testing the fill and seal process. The pack may leak or fail in transit. Also, do not assume that a stock pouch will fit your product. Fill weight, bulk density and piece size affect the fill level and the bag dimensions.
Finally, check the lead time and MOQ before finalising the artwork. Digital printing allows low MOQs and fast turnaround, but the unit cost is higher. Rotogravure offers lower unit costs but needs longer runs and longer lead times. Match the order to your sales forecast and cash flow. Request free stock pouch samples to check material feel and barrier before committing to a custom print run. You pay only the courier cost.