What Is the Relationship Between Food Safety and Packaging?

What Is the Relationship Between Food Safety and Packaging?

The relationship between food safety and packaging goes far beyond simply protecting food from the external environment. Packaging provides an important layer of protection against physical, chemical, and microbiological hazards as food travels from production to the consumer. However, packaging can itself become a food safety risk if it is poorly designed or manufactured from unsuitable materials.

For this reason, modern food safety practices view packaging not merely as a commercial element that enhances a product’s appearance and marketability, but as an integral part of the product safety system.

Numerous factors can affect product safety, including packaging raw materials, printing inks, adhesives, coatings, production conditions, storage conditions, transportation, and the duration of contact with food. Particularly for packaging that comes into direct contact with food, migration—the transfer of chemicals from packaging materials into food—is a key issue that must be assessed from a food safety perspective.

Consequently, controlling raw materials, processes, and production environments alone is not enough to produce safe food. Food-contact packaging must also be managed using the same risk-based approach.

Where Does Packaging Fit into Food Safety?

When considering the chain of activities that affect product safety in a food business, packaging often appears to be one of the final stages of production. In reality, packaging safety begins much earlier.

Packaging safety encompasses all of the following processes:

• Selection of packaging raw materials,
• Packaging design,
• Compatibility of materials with food,
• Packaging manufacturing processes,
• Printing and coating applications,
• Adhesives and auxiliary chemicals,
• Hygiene of the packaging production environment,
• Foreign material control,
• Storage of packaging materials,
• Transportation conditions,
• Delivery to the food manufacturer,
• Filling and packing operations,
• Interaction between packaging and the finished product throughout its shelf life.

A failure of control at any point in this chain may cause a food product that was initially safe to pose a risk by the time it reaches the consumer.

What Is the Primary Role of Packaging in Food Safety?

One of the main functions of packaging is to create a controlled barrier between food and environmental hazards.

This barrier helps protect food from:

• Microorganisms,
• Dust,
• Dirt,
• Foreign materials,
• Changes in moisture,
• Oxygen,
• Light,
• Odors,
• Chemical contamination,
• Physical damage that may occur during transportation

This helps protect the food.

However, the required barrier properties are not the same for every product. For example, an oxygen barrier may be critical for a fatty product susceptible to oxidation, whereas water vapor permeability may be more important for another product affected by moisture loss.

Therefore, choosing appropriate packaging requires consideration not only of its durability and cost, but also of its suitability for the product’s safety, shelf life, and chemical characteristics.

How Does Packaging Protect Food Against Microbiological Hazards?

Microorganisms are among the main causes of food spoilage and foodborne illness. Packaging helps reduce the risk of microbiological contamination by limiting contact between the product and the external environment.

Properly sealed packaging that maintains its integrity makes it more difficult for bacteria, molds, and other microorganisms to reach the product.

However, the opposite may occur if the packaging itself is not manufactured or stored under hygienic conditions. Microorganisms present on the food-contact surface of packaging can be transferred directly to the product during packing.

Therefore, important components of product safety systems at food packaging manufacturers include:

• Personnel hygiene,
• Cleaning and sanitation,
• Pest control,
• Raw material management,
• Hygienic design of production areas,
• Protection of packaging materials,
• Storage conditions

These are essential elements of the product safety system.

What Is Chemical Migration?

One of the most important considerations in food packaging is migration.

Migration refers to the transfer of certain chemical constituents from packaging materials into food. This phenomenon is not limited to plastic packaging. Various food-contact materials, including plastics, paper, cardboard, metals, coatings, printing inks, and adhesives, may need to be evaluated.

Scientific studies show that migration can vary depending on the structure of the packaging material, the composition of the food, temperature, contact time, and environmental conditions.

A recent academic review published in the Journal of Food Science indicates that chemical migration from packaging into food should be systematically assessed in terms of food safety and public health. The relevant study can be read under the title Food Packaging and Chemical Migration: A Food Safety Perspective.

Which Factors Affect Migration?

Chemical transfer from packaging to food is not a fixed phenomenon. Many factors can alter the amount of migration.

In particular, the following factors may influence the result:

• Contact time,
• Temperature,
• Chemical composition of the packaging material,
• Fat content of the food,
• Acidity of the food,
• Moisture content,
• Contact surface area between the packaging and the food,
• Storage duration,
• Heat treatment conditions,
• Whether the packaging consists of one layer or multiple layers

can all influence the outcome.

For example, placing very hot food in packaging designed for use at room temperature may alter its expected migration behavior.

Likewise, the interaction between packaging and a high-fat food may differ from that involving a dry food.

Therefore, packaging suitability should not be judged solely on the general statement “suitable for food contact.” Consideration must also be given to the food categories, temperatures, and duration of use for which the packaging is intended.

A recent study published in Food Chemistry also highlights the importance of assessing chemical transfer from packaging into food in the context of contact conditions and packaging–food interactions. The relevant publication is available at Migration of Chemical Substances from Packaging Materials to Food.

Can Packaging Itself Become a Hazard to Food?

Yes. While packaging serves as a protective barrier for food, it may also become a potential source of hazards if it is not properly managed.

Packaging-related risks can generally be divided into three main categories:

• Chemical hazards: Transfer of packaging constituents, printing inks, adhesives, coatings, or other chemicals.
• Physical hazards: Plastic fragments, metal fragments, sharp edges, or other foreign materials.
• Microbiological hazards: Contamination caused by unhygienic production, storage, or transportation conditions.

Therefore, packaging suppliers should not be selected solely on the basis of price, delivery time, and print quality. Product safety performance must also be an integral part of supplier evaluation.

Why Are Printing Inks and Adhesives in Packaging Important?

Food packaging is often made of more than one substance. Modern packaging structures may contain various films, coatings, inks, lacquers, and adhesive systems.

In multilayer flexible packaging, different layers must be bonded together. In printed packaging, inks constitute another component of the packaging structure.

The fact that these substances are not intended to come into direct contact with food does not eliminate the need for a risk assessment. Depending on the packaging structure, manufacturing process, and storage method, substances may migrate through different mechanisms.

A comprehensive scientific review published in the journal Foods shows that transfer mechanisms such as contact migration, gas-phase migration, penetration, and set-off must be considered when evaluating packaging safety. The study is available at Migration of Chemical Compounds from Packaging Materials into Packaged Foods.

What Is Set-Off Migration?

Set-off is a particularly important concept in the management of printed packaging.

When printed packaging materials are wound into rolls or stacked, the printed surface may come into contact with a surface that will later touch food. Without appropriate process controls, ink constituents may transfer onto that food-contact surface.

For this reason, the following should be considered together in packaging manufacturing:

• Selection of inks,
• Drying or curing conditions,
• Control of the printing process,
• Roll winding or stacking conditions,
• Intended use of the packaging

These factors should be assessed collectively.

What Are IAS and NIAS?

Two concepts of increasing importance in packaging safety are IAS and NIAS.

IAS – Intentionally Added Substances refers to substances deliberately used in the manufacture of packaging or to achieve its intended performance.

NIAS – Non-Intentionally Added Substances refers to substances that are not deliberately added to packaging but may arise from manufacturing, degradation, reactions, or other processes.

NIAS make food safety assessment particularly important in complex packaging systems, because controlling only the substances intentionally used in a packaging formulation may not always be sufficient.

Scientific assessments concerning NIAS and plastic food-contact materials are discussed in detail in the publication Safety of Plastic Food Packaging: The Challenges about Non-Intentionally Added Substances.

Why Is Regulatory Compliance Important for Food-Contact Materials?

The safety of food packaging is not a matter left solely to the voluntary quality practices of businesses. Many countries have regulatory requirements for materials that come into contact with food.

Under the European Union’s approach, food-contact materials include not only packaging but also processing machinery, containers, and other materials that come into contact with food.

The European Commission notes that the transfer of constituents from food-contact materials into food may affect chemical safety, product quality, and characteristics such as taste and odor. Food-contact materials placed on the European market are generally expected to comply with the framework established by Regulation (EC) No 1935/2004 and relevant good manufacturing practices.

For the current regulatory approach, see the European Commission – Food Contact Materials resource.

How Does the FDA Evaluate Packaging Safety?

The U.S. Food and Drug Administration (FDA) also assesses food-contact substances from a food safety perspective.

Under the FDA’s approach, food packaging, packaging components, certain adhesives, colorants, and various materials that come into contact with food may fall within the scope of assessment.

The amount of a substance that may migrate from packaging into food, and the resulting level of consumer exposure, are important factors in risk assessment.

The FDA’s current guidance can be followed through the resource Food Packaging & Other Substances that Come in Contact with Food.

What Is the Relationship Between Packaging and Shelf Life?

One function of packaging is to help keep a product safe and maintain its intended quality characteristics throughout its designated shelf life.

Oxygen, moisture, light, and environmental contamination can influence the rate at which many products deteriorate. Choosing appropriate packaging barrier properties can reduce the impact of these factors on the product.

For instance, packaging with a suitable oxygen barrier may limit oxidative changes in an oxygen-sensitive product. For moisture-sensitive products, a water vapor barrier can be important in maintaining product characteristics.

However, strong barrier performance alone does not mean that packaging is safe. Barrier performance, chemical compliance, mechanical strength, migration characteristics, and conditions of use must be evaluated together.

What Is Active Packaging?

Conventional packaging primarily aims to create a passive barrier between the product and its environment. Active packaging systems, by contrast, can interact actively with conditions inside the package.

For example, some active packaging solutions may be developed to:

• Absorb oxygen,
• Control moisture,
• Release specific substances,
• Support product shelf life

These functions can be incorporated into active packaging designs.

Although these technologies offer significant advantages, the safety of the active components used and their potential migration behavior must be evaluated.

How Do Intelligent Packaging Systems Contribute to Food Safety?

Rather than directly altering the food, intelligent packaging systems may be designed to provide information about the product or the environment surrounding its packaging.

For example, systems that monitor temperature changes or whether a product has been exposed to particular conditions may support more effective supply chain management.

Such technologies have the potential to improve traceability and decision-making, especially for products requiring a cold chain.

The European Food Safety Authority’s (EFSA) current scientific approach to active and intelligent food-contact materials can be followed through the EFSA Food Contact Materials resource.

How Does Packaging Integrity Affect Food Safety?

Selecting the correct packaging material is not enough. The packaging must maintain its integrity throughout the product’s shelf life.

Packaging that is punctured, torn, cracked, or improperly sealed may compromise the protective barrier between the product and the external environment.

Therefore, packaging operations should include product-specific controls for:

• Seal or bonding integrity,
• Proper closure of lids and caps,
• Packaging thickness,
• Puncture resistance,
• Resistance to damage during transportation,
• Leak tightness

These characteristics should be checked according to the product’s requirements.

Why Must Food Characteristics Be Considered When Selecting Packaging?

Not every type of packaging is suitable for every food product.

When selecting packaging, the following product characteristics should be assessed:

• Fat content,
• pH value,
• Water activity,
• Moisture content,
• Consumption temperature,
• Filling temperature,
• Heat treatment requirements,
• Shelf life,
• Storage temperature,
• Sensitivity to light and oxygen

These factors must be taken into account.

For example, packaging designed for cold use may not be suitable for products filled at high temperatures. Similarly, a material evaluated only for dry foods should not be assumed to perform equally well with fatty or acidic foods.

How Should Food Safety Be Assessed in Recycled Packaging?

The increasing use of recycled materials in the packaging industry in response to sustainability goals is an important development. However, environmental sustainability and food safety must be considered together.

When using recycled materials, businesses should assess control of the material source, the effectiveness of the recycling process, possible contaminants, intended use, and applicable regulatory criteria.

The fact that packaging is environmentally friendly does not automatically mean that it is suitable for food contact. Likewise, the sustainability performance of safe food packaging must be evaluated separately.

The appropriate approach is to integrate safety, quality, regulatory compliance, and sustainability criteria into the same design process.

Why Is the BRCGS Packaging Standard Important?

One of the key international frameworks for systematically managing product safety and quality in the packaging industry is the BRCGS Packaging Materials standard.

BRCGS Packaging Materials helps packaging manufacturers establish a systematic framework for producing products that are safe, legally compliant, and capable of meeting customer expectations.

The current BRCGS Packaging Materials Issue 7 framework places emphasis on areas such as product safety culture, hazard analysis and risk assessment, quality management, site standards, product control, process control, and personnel.

Packaging manufacturers and food safety professionals can gain a detailed understanding of the standard’s structure and requirements through Integral Bureau’s BRCGS Packaging Materials Issue 7 Basic Awareness Training.

Other programs offered under BRCGS can be found on the BRCGS Approved Training page.

What Does BRCGS Packaging Materials Issue 7 Focus On?

Key areas covered by BRCGS Packaging Materials Issue 7 include:

• Senior management commitment,
• Product safety culture,
• Hazard analysis and risk assessment,
• Quality management system,
• Site standards,
• Product control,
• Process control,
• Personnel management

These are among its principal areas of focus.

This framework demonstrates that packaging safety cannot be managed through laboratory testing alone. Safe packaging production requires an integrated system covering everything from management systems to suppliers, production areas to personnel, and risk analysis to verification.

Why Is HARA Important in Packaging Manufacturing?

Identifying hazards and systematically evaluating risks is essential in the packaging industry.

Using the HARA approach, a business can systematically assess:

• Which hazards could arise,
• Where each hazard could occur,
• The level of risk,
• Which control measures should be applied,
• How the effectiveness of controls will be verified

These issues can be evaluated systematically.

This approach helps packaging businesses manage product safety proactively rather than reactively.

Is There a Connection Between HACCP and Packaging Safety?

Although HACCP is most often associated with food manufacturing, packaging safety is not entirely separate from a food manufacturer’s HACCP system.

When conducting HACCP studies, food manufacturers should also assess hazards that may arise from packaging materials entering their production processes.

For example, the following may need to be considered:

• Chemical migration,
• Physical hazards arising from packaging fragments,
• Use of incorrect packaging,
• Incorrect product information on packaging,
• Microbiological contamination of packaging

These hazards may be included in the assessment, depending on the product and process.

Professionals seeking to develop their ability to identify food safety hazards systematically can explore Integral Bureau’s Advanced HACCP Training program.

What Should You Consider When Selecting a Packaging Supplier?

Selecting a packaging supplier is an important decision within a food safety system.

Comparing prices alone is not sufficient when evaluating suppliers. The following criteria should also be considered:

• Suitability for food contact,
• Regulatory compliance documentation,
• Technical specifications,
• Migration assessments,
• Manufacturing hygiene,
• Product safety management system,
• Change management,
• Traceability,
• Complaint performance,
• Previous nonconformities,
• Audit results,
• Relevant certifications, such as BRCGS.

As the level of risk increases, supplier approval methods are expected to become more comprehensive.

Why Is a Packaging Specification a Critical Document?

Having a clear, up-to-date technical specification for each type of packaging used in a food business supports safe procurement management.

A well-prepared packaging specification may define, where applicable:

• Material structure,
• Dimensions,
• Thickness,
• Barrier properties,
• Food-contact compliance,
• Appropriate conditions of use,
• Temperature limits,
• Printing specifications,
• Physical performance criteria,
• Legal requirements

These characteristics can be specified as needed.

It is important that specifications are not treated separately from purchasing agreements and that they are mutually agreed upon with suppliers.

Why Must Packaging Changes Be Controlled?

Changes made by a packaging supplier to formulations, raw materials, inks, adhesives, manufacturing processes, or production facilities may introduce new product safety risks.

Change management is therefore a fundamental element of packaging safety.

Before introducing new packaging or modifying an existing structure, it may be necessary to review the risk assessment, obtain the required compliance documents, and repeat relevant tests when appropriate.

Why Is Packaging Traceability Necessary?

In a food safety incident, it is critical to identify quickly which batch of packaging was used in which food production batch.

An effective traceability system helps establish links:

• From packaging raw materials to production,
• From production to dispatch,
• From packaging suppliers to food manufacturers,
• From food manufacturing to finished products

These connections support end-to-end traceability.

Traceability can help identify affected products more accurately during potential recalls and avoid unnecessarily expanding the scope of a recall.

Do Packaging Storage Conditions Affect Food Safety?

Yes. Packaging manufactured safely can become contaminated as a result of unsuitable storage conditions.

Packaging should be protected against:

• Dust,
• Moisture,
• Pests,
• Chemicals,
• Strong-smelling substances,
• Physical damage,
• Unsuitable temperatures

Appropriate protection must be maintained.

In particular, leaving food-contact packaging surfaces exposed during storage may pose a significant contamination risk.

Why Is Personnel Training Necessary for Packaging Safety?

Even the best-designed management system cannot be implemented effectively if employees do not understand its requirements.

A minor mistake by personnel involved in packaging manufacturing may result in foreign material contamination, use of an incorrect raw material, printing errors, or other problems affecting product safety.

Employees therefore need regular training on the risks associated with their responsibilities.

Organizations seeking to build competencies in quality, product safety, and packaging standards can explore Integral Bureau’s training services and BRCGS Packaging Materials Issue 7 Lead Auditor / Auditor Training programs.

How Should Food Manufacturers Manage Packaging Safety?

Food businesses should not regard packaging safety as the sole responsibility of the purchasing department.

An effective packaging safety system requires collaboration among quality, food safety, procurement, R&D, production, warehousing, and, where necessary, regulatory affairs teams.

A basic approach may involve the following steps:

1. Identifying product characteristics,
2. Defining conditions of packaging use,
3. Analyzing packaging-related hazards,
4. Selecting suitable suppliers,
5. Preparing technical specifications,
6. Verifying compliance documentation,
7. Evaluating necessary migration and performance tests,
8. Defining incoming inspection controls,
9. Ensuring traceability,
10. Monitoring supplier performance,
11. Controlling changes,
12. Reviewing the system regularly.

Summary: The Relationship Between Food Safety and Packaging

Food safety and packaging are two areas that cannot be considered independently of each other.

Appropriate packaging:

• Protects food from environmental contamination,
• Reduces physical damage,
• Helps manage the risk of microbiological contamination,
• Controls factors such as oxygen, moisture, and light,
• Supports product shelf life,
• Helps maintain product integrity throughout the supply and distribution chain.

By contrast, packaging that is poorly designed, has not been verified for compliance, or is manufactured under uncontrolled conditions may lead to:

• Chemical migration,
• Physical contamination,
• Microbiological contamination,
• Loss of packaging integrity,
• Product safety and regulatory compliance problems

These are among the potential consequences.

Packaging should therefore not be seen as the final step in the food safety system, but as a strategic component of the supply chain extending from raw materials to the consumer.

Frequently Asked Questions

Does food packaging directly affect food safety?
Yes. While packaging protects food from external contamination, it can also become a source of hazards through unsuitable materials, migration, physical foreign materials, or inadequate hygiene.

Can chemicals migrate from packaging into food?
Under certain conditions, chemical constituents may migrate from packaging into food. This phenomenon is known as migration. The amount transferred may vary depending on the material, food characteristics, temperature, and contact time.

Can the same packaging be used for every food product?
No. Packaging selection must consider factors such as the food’s fat content, acidity, moisture, filling temperature, storage conditions, and shelf life.

Is a food-contact compliance certificate sufficient on its own?
Although a general declaration of compliance is important, actual conditions of packaging use must also be evaluated. Food type, temperature, contact time, and processing conditions all matter when assessing packaging suitability.

What is migration testing?
Migration tests assess substances that may transfer from packaging into food or suitable food simulants. Test conditions should be determined based on the packaging’s intended conditions of use.

Can printed packaging pose a food safety risk?
Printing inks and other packaging components can pose risks if they are not selected appropriately or the process is not properly controlled. Therefore, printing structure, curing, set-off, and intended end-use conditions must be considered.

What does NIAS mean?
NIAS stands for Non-Intentionally Added Substances. These are substances not deliberately added to packaging but which may arise during manufacturing, chemical reactions, or degradation.

What is BRCGS Packaging Materials?
BRCGS Packaging Materials is an international standard for systematically managing product safety, quality, legality, and operational controls in packaging and packaging material manufacturing. The current issue is Issue 7.

Who should be familiar with BRCGS Packaging Materials Issue 7?
The standard is relevant to packaging manufacturers, quality managers, product safety teams, food packaging suppliers, auditors, consultants, and professionals working throughout the packaging supply chain.

Is HACCP applied by packaging manufacturers?
Hazard analysis and risk assessment are essential to risk-based product safety management in the packaging industry. Food manufacturers must also assess potential packaging-related hazards within their own HACCP systems.

Is recycled packaging safe for food?
The use of recycled materials alone does not establish whether packaging is safe or unsafe. Material sourcing, the recycling process, intended use, applicable legislation, and food-contact compliance must be evaluated together.

What is the biggest mistake in packaging safety?
One major mistake is evaluating packaging only in terms of price, design, and physical strength. Effective packaging safety management must also consider chemical compliance, hygiene, migration, conditions of use, supplier reliability, and traceability.

Is BRCGS certification mandatory for packaging suppliers?
This depends on customer, market, contractual, and supply chain requirements. Nevertheless, implementing a structured product safety system such as BRCGS Packaging Materials can help packaging manufacturers manage their risks systematically and provide assurance to customers.

What training is available in food safety and packaging?
Depending on the role and industry, relevant training may include BRCGS Packaging Materials Issue 7, hazard analysis and risk assessment, HACCP, internal auditing, root cause analysis, and product safety culture. Integral Bureau’s BRCGS-approved and food safety-focused training programs offer options designed to develop professionals’ competencies in these areas.