When I launched TeaSquares, I thought I had my packaging figured out. I started with simple stand-up pouches—affordable, easy to source, and they looked great. But I quickly ran into problems.

I learned the hard way that packaging is what protects your product, extends shelf life, and ensures customers have the best experience possible. The right packaging helps prevent staleness, keeps flavors intact, and makes it easy for customers to store and use your product. The wrong packaging? It can lead to wasted product, poor customer reviews, and lost sales.

For many brands, flexible packaging—like pouches and high-barrier films—has become the best solution. It’s cost-effective, reduces material waste, and gives you a ton of branding space. But not all flexible packaging is created equal. In this guide, I’ll break down what you need to consider for snacks, bars, dry goods, and sauces/ready-to-heat foods so you can avoid the mistakes I made and get it right the first time.

This article is part of our series on packaging considerations across different categories. Read our articles on packaging for Refrigerated and Frozen products.

1. Snacks (Cookies, Chips, Crackers)

Barrier Protection to Maintain Crunch and Freshness

Shelf-stable snacks are highly sensitive to moisture, oxygen, and light, which can quickly make them stale, soggy, or lose their crunch. If you’ve ever opened a bag of chips that felt stale right out of the package, you know how critical proper packaging is.

What your packaging must do:

• Use high-barrier films: Multi-layer films with moisture and oxygen barriers (like PE, PP, or metalized PET) help preserve texture and flavor.
• Choose a strong seal: Heat-sealed edges prevent air leaks that cause snacks to go stale.
• Block light exposure: If your product contains delicate ingredients like nuts or chocolate, consider opaque or UV-blocking films to prevent oxidation.

Resealable Packaging for Consumer Convenience

Once a snack package is opened, it’s at risk of going stale fast. Resealable options help extend freshness and improve usability.

Best resealable options:

✔ Zipper pouches for cookies and crackers to lock in freshness after opening.

✔ Press-to-close seals for chips, making it easier for customers to store.

✔ Single-serve portion packs to keep product integrity while providing grab-and-go convenience.

At TeaSquares, we initially didn’t use resealable packaging, thinking our customers would eat the bars in one sitting. We quickly learned that people love to snack throughout the day, and resealable pouches made a huge difference in repeat purchases.

2. Energy and Protein Bars

Preventing Dryness and Maintaining Texture

Energy bars are sensitive to moisture loss—if the packaging isn’t designed right, bars can dry out, become rock hard, or crumble before they’re eaten.

What your packaging must do:

• Use moisture-barrier films: Low-moisture transfer films (like metalized or EVOH-layered films) keep bars soft and chewy.
• Seal edges tightly: Poorly sealed wrappers let air in, making bars dry or stale.
• Consider flow wrap packaging: This provides a tight seal while being efficient for high-speed production.

Single-Serve, Easy-to-Open Formats

Customers expect protein and energy bars to be portable, durable, and easy to open—especially for on-the-go consumption.

Best packaging solutions:

✔ Flow-wrapped film with an easy-tear notch for single bars.

✔ Multipack pouches for value packs while maintaining freshness.

✔ Eco-friendly options like compostable wrappers for sustainability-focused brands.

3. Dry Goods (Flours, Grains, Baking Mixes, Spices)

Barrier Protection Against Moisture and Oxygen

Dry goods like flour, grains, and spices need strong moisture barriers to prevent clumping, spoilage, and contamination.

What your packaging must do:

• Use high-barrier laminated films: These prevent moisture absorption and keep products shelf-stable longer.
• Include resealable zippers: Prevents spillage and keeps products fresher after opening.
• Consider stand-up pouches: These provide durability, prevent leaks, and maximize branding space.

At TeaSquares, we learned that moisture is the biggest enemy of dry goods. If customers stored our product in a humid environment, it clumped together. Upgrading to multi-layer moisture-resistant film made a huge difference in product quality.

4. Sauces & Ready-to-Heat Foods

Preventing Leaks, Spills, and Spoilage

Liquid and semi-liquid products need strong, leak-proof packaging that protects against punctures and transport damage.

What your packaging must do:

• Use durable multi-layer laminates: These provide puncture resistance and protect against leaks.
• Ensure heat-sealed edges: Weak seals can lead to burst pouches.
• Consider spouted pouches: These offer mess-free pouring for sauces and broths.

Extending Shelf Life Without Refrigeration

For ready-to-heat foods that don’t require refrigeration until opening, packaging plays a key role in maintaining freshness.

Best packaging solutions:

✔ Aseptic packaging for sauces and purees, allowing them to remain shelf-stable for months.

✔ Vacuum-sealed flexible pouches to extend shelf life without preservatives.

A common mistake brands make? Using low-barrier films for high-acid sauces, which leads to flavor degradation. Make sure your packaging has the right chemical resistance for your product!

5. Sustainable Packaging Considerations

Balancing Sustainability with Performance

Consumers today expect sustainable packaging, but you have to balance eco-friendliness with functionality.

What your packaging must do:

• Use recyclable mono-material films to make it easier for consumers to recycle.
• Explore compostable packaging if your product has a shorter shelf life.
• Reduce material waste with thinner, high-performance films that maintain barrier protection.
• Use water-based or plant-based inks to reduce environmental impact.

Finding the Right Packaging Partner

The right packaging doesn’t just protect your product—it builds trust with customers, reduces waste, and ensures a better experience. Whether you’re packaging snacks, bars, dry goods, or sauces, you need strong barrier protection, convenience, and sustainability.

This is where Josh Packaging comes in. They offer:

✔ High-barrier films and resealable pouches to keep snacks, bars, and dry goods fresh.

✔ Durable, leak-proof liquid packaging with spouted options for easy use.

✔ Sustainable packaging solutions like recyclable and compostable films to help brands meet environmental goals.

If you’re looking for high-quality, customized packaging for your shelf-stable products, Josh Packaging can help. Reach out today to explore how their solutions can support your brand’s needs.