How to Prevent Packaging Material Degradation Caused by Chemicals: Practical Tips for Manufacturers

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Manufacturers of consumer goods and chemical products often face packaging material degradation due to aggressive substances. Whether it’s plasticizer migration, chemical corrosion of metal packaging, or loss of plastic strength, the consequences can be serious—from product contamination to breaches of safety regulations. The issue affects not only storage but also transportation and long-term stability. How do you select materials that resist specific chemical influences? And what factors should be considered when testing compatibility?

Why Packaging Degrades and How to Identify It

Degradation of packaging materials due to chemical substances is a common problem for manufacturers who store or distribute aggressive liquids, powders, or pastes. Damage occurs when chemical components in the product react with polymers, metal layers, or adhesives in the packaging. Typical symptoms include discoloration, loss of strength, cracks, swelling, or leakage. In plastic packaging, degradation can begin upon contact with organic solvents, acids, or alkalis, which disrupt polymer chains. Metal packaging, on the other hand, corrodes when exposed to chlorides, sulfates, or moisture. It is crucial to distinguish between surface changes and structural damage—while the former may be an aesthetic issue, the latter compromises the integrity and safety of the entire package.

Early detection of degradation requires regular inspections, especially for long-term stored products. It is recommended to test mechanical properties (e.g., tensile strength) and chemical resistance using standard testing methods. For transparent packaging, haze or changes in transparency can be monitored, while for opaque packaging, weight loss or deformation should be observed. It is also important to monitor storage conditions—temperature, humidity, and UV radiation can accelerate degradation. If the first signs of damage appear, it is necessary to reassess the compatibility of the packaging with its contents and consider alternative materials.

Choosing the Right Material: How to Prevent Incompatibility

Selecting the correct packaging material is fundamental to ensuring the long-term durability and safety of a product. When choosing, it is essential to consider the chemical composition of the stored substance, its pH, polarity, and potential for additive migration. For example, polyethylene (PE) is resistant to aqueous solutions but may degrade upon contact with aromatic hydrocarbons. Polypropylene (PP) is more suitable for organic solvents, while polyethylene terephthalate (PET) resists oils and alcohols. For aggressive chemicals such as concentrated acids or alkalis, multilayer packaging with barrier layers (e.g., EVOH or aluminum foil) is often used to prevent substance penetration.

For manufacturers, it is crucial to collaborate with raw material suppliers and conduct compatibility tests before starting mass production. These tests involve exposing the packaging to the chemical substance for a defined period at various temperatures, followed by an evaluation of mechanical and chemical properties. It is also important to consider legislative requirements, such as the REACH regulation, which restricts the use of certain substances in packaging for food or cosmetics. In case of uncertainty, it is advisable to consult material selection with polymer chemistry experts or certified laboratories.

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Surface treatments and additives: How to enhance packaging durability

If it is not possible to change the base packaging material, its resistance can be significantly improved through surface treatments or the addition of special additives. Surface treatments, such as plasma cleaning, fluorination, or the application of thin protective layers (e.g., SiOx), create a barrier against chemical aggression. Fluorination, for example, increases the resistance of polyolefins to organic solvents, while plasma treatment improves the adhesion of coatings and adhesives. These methods are particularly suitable for packaging that comes into direct contact with aggressive liquids.

Another option is the use of additives that stabilize the polymer structure. Antioxidants slow down degradation caused by oxygen and heat, UV stabilizers protect against photodegradation, and antistatic agents reduce the risk of electrostatic charging, which can attract dust and impurities. For packaging exposed to high temperatures, thermal stabilizers are used, while for cold environments, plasticizers are suitable to prevent brittleness. When selecting additives, it is important to ensure their compatibility with the packaging contents and to adhere to the maximum permitted concentrations in accordance with applicable regulations.

Storage and Handling: Practical Tips for Minimizing Risks

Even the most durable packaging can degrade if not stored and handled correctly. The basic rule is to adhere to the temperature and humidity conditions recommended by the packaging manufacturer and the stored chemicals. High temperatures accelerate chemical reactions and can cause softening or deformation of plastics, while low temperatures increase brittleness. Humidity, in turn, promotes corrosion of metal packaging and the hydrolysis of certain polymers. Ideal storage conditions include a temperature between 15–25 °C and relative humidity below 60%. For sensitive products, climate-controlled storage is recommended.

Proper handling of packaging is also crucial – mechanical stress, drops, or friction can damage protective layers and accelerate degradation. During transport, it is advisable to use pallets and protective packaging to minimize vibrations and impacts. For liquids, care must be taken to fill the packaging correctly – an overfilled container may burst due to temperature fluctuations, while an underfilled one may deform. Regular inspection of stored packaging and documentation of storage conditions help detect issues early and prevent financial losses.

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Testing Packaging Compatibility with Chemicals: When and How to Perform It

Testing the compatibility of packaging materials with chemicals should be an integral part of the development of every product, especially if it contains aggressive or reactive components. The standard procedure includes exposure tests, during which packaging samples are subjected to the action of the given chemical for a specified period – usually 28 days at a temperature of 23 °C or higher, if relevant to real-use conditions. During the test, changes in mechanical properties (strength, elasticity), optical parameters (haze, color change), and chemical stability (e.g., migration of substances into the contents) are monitored.

For manufacturers, it is crucial to conduct tests not only on new materials but also when changing the formulation of the filled product or the packaging supplier. It is recommended to combine laboratory tests with real-world tests under operational conditions, as factors such as vibrations, temperature fluctuations, or mechanical stress can accelerate degradation. Test results should be documented and serve as a basis for certification under REACH regulations or for internal quality standards.

How to Address Packaging Degradation in Practice: Corrective Measures and Prevention

If packaging degradation occurs during storage or transport, the cause must first be identified. The most common culprits are incorrectly selected material, insufficient surface treatment, or contamination of the packaging during production. In acute cases, temporary solutions such as repackaging the product into a compatible inner packaging (e.g., a film with barrier properties) or reducing storage temperature to slow down chemical reactions can be applied. However, these steps do not address the root cause and should be supplemented with long-term measures.

Preventing degradation requires a systematic approach: regular inspection of packaging upon goods receipt, employee training on proper handling and storage, and above all, collaboration with suppliers of chemical raw materials and packaging. For example, for surfactants or solvents, it is advisable to request a compatibility certificate with specific materials from the supplier. It is also important to monitor trends in packaging technologies, such as new types of polymers with higher chemical resistance or active packaging with absorption properties.

Environmental aspects: How to minimize the impact of packaging degradation on the environment

Packaging degradation not only affects product quality but also the environment. The release of substances from damaged packaging can lead to soil or water source contamination, especially if toxic or persistent compounds are involved. Manufacturers should therefore prioritize materials that are not only chemically resistant but also recyclable or biodegradable. For example, high-density polyethylene (HDPE) is resistant to many chemicals and is also highly recyclable, whereas some composite materials may pose challenges.

Another step is optimizing packaging thickness—walls that are too thick increase material consumption, while walls that are too thin may lead to premature degradation. Modern simulation software allows modeling of packaging behavior under various conditions to find the ideal balance between durability and environmental footprint. It is also important to adhere to circular economy principles, for instance, by designing packaging that is easy to disassemble and recycle or by using materials from recycled sources.

Need help selecting packaging materials?

Every chemical raw material requires an individual approach. GCG Group provides detailed technical data sheets and safety data sheets (SDS) with information on compatibility with packaging materials for all products. Our experts will help you select the optimal solution for your application and minimize degradation risks. Contact us – or browse our catalog of over 1,300 products right away.