May 24, 2023

Best Material and Printing for Packaging of Chips

Quality packaging plays a crucial role in the sales of any product, as well as the reputation of every brand, and this is very true when it comes to chips. 

Being one of the most commonly eaten snacks in the world, chips require premium packaging that doesn’t just preserve their flavor and freshness but also captures consumers’ attention to make purchases. Choosing the right material and printing technique can affect the overall appeal and shelf life of chips packaging.

In this article, we will further elaborate on the importance of choosing proper packaging for chips, the best materials and printing methods, and so many more.

A Packet of Potato Chips

The Importance of Choosing Proper Packaging for Chips

The packaging of chips plays enormous importance in the quality of the snacks from production to consumption. High-quality packaging ensures that the chip’s taste and texture don’t degrade, boosting your brand’s goodwill.

Protecting Chips from Air and Moisture

With top-grade packaging, the chips will be protected from the detrimental effects of air and moisture. Being exposed to air makes the chips quickly become stale, and soft, and lose their loved crunchiness. On the other hand, moisture makes the chips soggy and spoil.

But with proper packaging, there will be an effective barrier to stop air and moisture from penetrating. This guarantees that the chips will maintain their freshness, flavor, taste, and texture, ensuring that consumers covet more after every bite.

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Extend the Shelf Life of Potato Chips

The type of packaging used has a significant influence on the shelf life of potato chips. A package that possesses high oxygen and moisture barrier properties can prolong the freshness and crispiness of the chips. 

By using potato chip packaging that minimizes the entry of oxygen, oxidation will be prevented. This also reduces moisture absorption, ensuring that the chips’ quality stays preserved over an extended period.

Hence, with the right storage, your chips will remain enticing and delectable for a longer duration. This prevents product waste, boosts customer satisfaction, and reduces the overall cost of production.

Protect Chips during Transportation and Handling

During transportation and handling, chips are likely to get crushed or broken because of their fragile nature. This results in unappealing products and potential customer dissatisfaction. To avoid this, inflatable pouches must be used. Afterward, they can be stored in corrugated boxes or rigid plastic containers for additional layers of protection.

All these measures ensure that the chips get to customers intact and in optimal condition. This helps to maintain customers’ trust and confidence in your brand.

Packaged Chips

Attract Consumers and Build Brand Image

The goal of effective packaging is not limited to the protection of products. In the real world, packaging also serves as a powerful marketing tool to attract customers and establish great brand goodwill. 

When professionally designed with eye-catching graphics, vibrant colors, and well-executed branding elements, the packaging can captivate consumers’ attention, making them choose your product over competitors.

Just like how the eyes get attracted to beautiful scenery, the creative use of typography, imagery, and visual elements can evoke emotions and convey the quality and taste of the chips. 

An appealing packaging design forms a positive perception of the brand and cultivates a memorable experience in the minds of consumers. This is very instrumental to gain more leads, brand loyalty, and repeated purchases.

Common Chips Packaging Material

There is a range of chip packaging material options, including plastic packaging, composite cans, and combinations of other materials.

Plastic Packaging

Polyethylene (PE) and polypropylene (PP) films are two common plastic materials that are used for packaging chips. They have outstanding properties, with PE offering excellent moisture resistance that prevents the chips from becoming stale or soggy, and PP offering heat resistance. 

This resistance is very important as moisture and heat can affect the texture and taste of the chips, which results in a bad consumer experience.

The moisture-resistant property of PE materials ensures the crispness and quality of the chips. PP materials offer good clarity, which allows consumers to see through the packaging, and have a look at the product. This tends to be advantageous for marketing and influencing purchase decisions.

Moreover, PE and PP are lightweight and cost-effective, making them ideal options for chip packaging. They can be easily crafted into different shapes and sizes, allowing you to create various appealing and functional packaging designs. Also, they support tight seals, which ensure the chips remain airtight, safe from external contaminants, and have a longer shelf life.

Plastic Film Potato Chips Packaging

Composite Can

Composite cans like rigid paper and paperboard containers have gained popularity in the packaging of chips. They have a sturdy paper body and metal or plastic ends, which provides stability and protection to the chips inside.

Composite cans are highly rated for their excellent structural integrity, which prevents chips from getting crushed or broken during transportation and handling. The strong structure plays a crucial role in ensuring that the shape and quality of the chips are preserved.

Moreover, composite cans give room for creative designs and eye-catching graphics, branding, and product information. With this, you can steal customers’ attention and increase sales.

Composite Cans Chips Packaging

Combination of Materials

Basically, potato chip bags consist of layers of different polymer materials strategically combined to provide optimal protection and functionality. These bags’ layered construction is designed to offer a balance of strength and flexibility. 

A common configuration includes Biaxially Oriented Polypropylene (BOPP) on the inside, a combination of Low-density Polyethylene (LDPE) and BOPP in the middle, and a thermoplastic resin on the outside.

The inside layer of BOPP offers excellent resistance to moisture and preserves the crispness of the chips by preventing moisture from entering the bag. BOPP also offers good clarity, allowing consumers to see the product inside the packaging.

The middle layer, which is composed of a combination of LDPE and BOPP, adds strength and flexibility to the bag. LDPE adds to the bag’s durability, ensuring it survives transportation and handling without damage. The inclusion of BOPP in the middle layer creates extra moisture and gas barrier properties. This further protects the chips from external factors.

Reinforced Paper Packaging for Chips

The outer layer is composed of thermoplastic resin for additional strength and safety. It shields the chips from light exposure, which can cause deterioration in taste and quality. Also, it provides a surface that enables the printing of vibrant graphics and branding elements, which boosts the visual appeal of the packaging.

The combination of these materials results in a highly functional chip bag that provides an optimal balance of strength, flexibility, moisture resistance, and visual appeal. This ensures that the chips remain fresh and protected throughout their shelf life.

Innovations and Trends in Chip Packaging

There are various innovations and trends in the chip packaging sector, and these are driven by sustainability concerns, aesthetic preferences, and consumer convenience. They showcase the evolving desires and preferences of consumers for a better snacking experience.

Customized Chips Packaging

Biodegradable Materials

The use of biodegradable materials in the packaging of chips is an important innovation to counter environmental concerns. Following the adoption of biopolymers, which are obtained from renewable sources, there is less reliance on fossil fuels and minimize carbon footprint.

 These materials break down naturally in the environment, reducing the long environmental hazards caused by traditional plastic films.

With the growing consumer demand for eco-friendly options and sustainable practices, biodegradable chip packaging provides the best approach to satisfaction. Many manufacturers are exploring these materials to contribute to a more sustainable environment and emphasize their dedication to reducing plastic waste and enhancing a greener future.

Minimalist Design

Driven by a desire for simplicity, beauty, and product visibility, the chip packaging minimalist design trend is gaining momentum. 

This design approach involves the incorporation of clean lines, subtle color palettes, and sharp graphics that showcase sleekness and a modern aesthetic. By minimizing visual clutter, the minimalist design shifts the focus to the product, displaying a sense of quality and sophistication.

The beauty of the minimalist design trend is that it doesn’t only appeal to customers who love a contemporary look, but also aligns with the desire for less wasteful and more sustainable packaging solutions. This innovation showcases the brands’ commitment to quality, simplicity, and great visual consumer experience.

Optimized Packaging Sizes and Shapes

In recent times, various packaging sizes (Learn: Practical Guidelines for Determining Optimal Packaging Size) and shape regulations are practiced, and these are driven by consumers’ convenience, portion control, and storage solutions.

Following this trend, single-serve and small-portion packaging are increasingly popular, as a means to promote portion moderation. This system offers many benefits, including convenience and reduction of food waste.

Another approach to this is using resealable pouches and stackable containers that help for continued storage in case the consumer doesn’t finish eating the chips. This optimized packaging solution provides greater flexibility in terms of preservation, portability, and improved blend with everyday lifestyles.

Beautiful Potato Chips Packaging Print

Popular Printing Techniques for Packaging of Chips

After choosing the best material and considering innovations and trends, the next important thing is to select the perfect printing technique for chip packaging.

There are 4 major types of printing techniques used for packaging chips. Each has its peculiarity, advantages, and applications. Let’s explore them quickly:

Flexographic Printing

This is a widely used technique for potato chip packaging because of its speed, versatility, and cost-effectiveness. It involves using flexible plates to transfer ink onto the packaging material. The great thing about flexographic printing is that it is compatible with any substrate, including plastic materials, composite cans, or a combination of materials.

Flexographic printing offers high-speed production and can be used with a wide variety of colors, producing good print quality. With the ability to print large volumes efficiently, this printing technique is well-suited for mass production and large-scale chip packaging projects at an inexpensive cost.

KTFP BP Series Color Flexo Printing Machine
Source: KETE

Rotogravure Printing

Another highly-rated technique is rotogravure printing. It’s popularly known for its exceptional print quality and fine details through the use of engraved cylinders to transfer ink onto the chips packaging material. 

The process involves the engraved cylinders holding ink in recessed cells, which are then transferred to the material. This printing technique offers vibrant colors, sharp images, and high-resolution graphics.

Rotogravure printing is often used for high-end chip packaging that requires intricate designs or special effects. While it offers superior print quality, it is generally more expensive and time-consuming than other printing methods. This printing method is ideal for premium chip brands that prioritize visual impact and love to create luxurious and eye-catching packaging.

KTHS B Series High Speed Rotogravure Printing Press
Source: KETE

Digital Printing

This is a spectacular printing mechanism that has gained popularity in the chip packaging sector because of its flexibility and quick turnaround time. It basically involves the use of computer-controlled equipment to transfer images directly on substrates. 

The digital images are printed directly onto the packaging material without the need for plates or cylinders as the case may be for other printing techniques.

Digital printing supports customization. Each package can feature unique designs or variations, making it suitable for limited edition or personalized chip packaging. With this technique, you will enjoy precise color control, high-resolution printing, and the ability to print on demand. 

Requiring a shorter setup time and minimal waste, digital printing is cost-effective for small to medium-sized chip production runs. You can also integrate variable data like barcodes or QR codes effortlessly.

Offset Printing

This is a popular printing technique used for packaging chips, especially with paper-based materials. The printing process involves moving ink from a plate to a rubber blanket and then onto the packaging material. 

Offset printing is highly rated for consistent and high-quality printing results, which result in sharp images and vibrant colors. It is a versatile printing method that is compatible with a wide range of materials.

Additionally, offset printing is cost-effective for medium to large production runs and is known for its efficient ink usage. It’s suitable for chip packaging that requires detailed designs, including product illustrations or complex graphics.

Manufacturing Process of Potato Chip Packaging

The manufacturing process of potato chips can be categorized into two divisions. The first is the process of making the packaging and the second is printing on the packaging. They are explained below:

Making the Packaging

The making of chip packaging involves several key steps with the first being the selection of the appropriate material. Popular materials used include plastic, composite can, and a combination of various materials.

Afterward, the packaging material is cut and shaped into the desired dimension, which is often formed into bags or containers that are sealed to preserve the chips.

Lastly, the potato chip packaging is put through quality control inspections to ensure compliance with the required standards. This includes cross-checking the dimension, sealing, and overall appearance.

Potato Chips Print Designs

Printing on the Packaging

To make the packaging prints, several processes are involved with the first being finalization of the design, artwork, and graphics to be incorporated. This includes optimizing the design for printability and accurate color reproduction.

The next step is to select the best printing technique to use, which could be flexographic, rotogravure, digital, or offset printing. The chosen technique should be one that can actualize your desired specifications. Then, decide on the type of ink to use and make sure they are compatible with the printing technique selected.

Finally, the prints can be made. But after that, they will undergo drying or curing processes for 100% adhesion and durability. Depending on your preference, you could apply some finishing touches like coatings for added protection and visual enhancement.

How to Choose Machines for Printing Packaging of Chips

Choosing the right printing machine is a determining factor in achieving high-quality and efficient printing of chip packaging. 

Before making the printing machine selection, you need to evaluate some elements, which include printing technology options, printing speed and capacity, substrate compatibility, printing quality and color consistency, workflow integration, and maintenance and support.

Premium Potato Chips Packaging
Premium Potato Chips Packaging

Printing Technology Options

When selecting a printing machine for chip packaging, it is vital to carry out an assessment of the available printing technology options. Different machines offer varying capabilities, like the number of colors that can be printed, the kind of materials they can work with, or the ability to integrate special effects like varnishes or coatings. 

Understanding the printing technology options helps you choose a machine that can reproduce your desired packaging design and visual appeal.

One of the best machines with unmatched printing technology options is the Super Speed Flexo Printer, which is compatible with various colors, and materials, and supports the incorporation of special effects. 

Another reliable printing machine is the Rotogravure Printer which takes your business to the next level. These are powerhouse technology innovations. Not only can they create stunning prints, they are perfect for large production runs, helping you meet tight deadlines.

Printing Speed and Capacity

Another crucial factor put into consideration is the printing speed and capacity of the machine. Before deciding on the best printing machine, evaluate your production demands and volume. It’s best to choose options that can handle bulk production as your business might grow in the near future. High-speed printing machines will increase production efficiency and output.

In terms of capacity, the maximum size and quantity of potato chip packaging the machine can produce should be taken into account. Make an evaluation of your production volume, order sizes, and growth projections to find out the perfect printing machine to accommodate your demands. 

While doing this, it’s very important to strike a balance between speed and capacity. This is to ensure optimal, consistent production, and minimized bottlenecks.

Substrate Compatibility

Not all printing machines are compatible with various kinds of substrates, which is why you need to check this out. The selected printer should be capable of blending with the specific materials used in the packaging of chips, such as plastic, composite can, and a combination of various materials. 

Assess the machine’s capability to handle different substrate types and thicknesses, as this will affect the print’s quality and ink adhesion.

Compatibility with various coatings or laminates may also be a requirement, especially for chip packaging that demands extra protection or better visual appeal. Other things worth checking include the printing plate system, drying or curing system, and tension control mechanism.

To be super sure you selected the right machine, you could test and verify the compatibility with specific chip packaging materials through sample runs or trials.

Printing Quality and Color Consistency

When choosing a printing machine for chip packaging, it is important to consider the printing quality and color consistency it can deliver. Evaluate the machine’s capability to make high-quality prints with sharp details, vibrant colors, and consistent results throughout the production run.

Also, you need to assess factors like the precision of the printing plates, ink control systems, registration accuracy, and color management. For every batch of print, consistent and accurate color reproduction is vital to maintaining brand identity and recognition.

To be 100% certain the right machine is selected, conduct print tests and examine sample prints. This will provide better insight into the printing quality of the machine.

Workflow Integration

Another element to consider when selecting a printing machine for the packaging of chips is seamless integration with existing workflows. Further assessment needs to be carried out for compatibility with design software, file transfer protocols, and workflow automation systems. Additionally, evaluate the machine’s ability to handle different types of prints efficiently and minimize downtime between print runs.

With the innovative pouch-making machine, you can be assured of a smooth integration of workflows that reduce potential bottlenecks. This machine is suitable for different industries, sizes, shapes, and materials.

Maintenance and Support

Before buying a printing machine, ensure the manufacturer offers adequate maintenance and support. Make inquiries about the manufacturer’s reputation for customer support, availability of spare parts, technical assistance, and training. This gives assurance of a smooth operation and minimized downtime.

Purchasing from a professional and reliable manufacturer like KETE will ensure uninterrupted operations with regular maintenance and timely support for maximizing the lifespan of the machine and eliminating disruptions to the production process.


Chips require quality packaging for them to retain their freshness, taste, and texture. There are various types of materials used for making the packaging, and this includes plastic, composite cans, and combinations of various materials.

The popular printing techniques used for the packaging of chips include flexographic printing, rotogravure printing, digital printing, and offset printing. However, before deciding on the type of material and printing technique to use, you must consider some determining factors.

Check here for information on related topics. You can also consult us for professional assistance and the provision of the most cost-effective packaging and printing machines.

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