If you’re concerned that your baked goods reach the consumer as fresh as they come out of the oven, you need a solution that’s up to the task. In the bakery and confectionery industry, maintaining the texture, organoleptic properties and presentation of baked goods is a daily challenge.
From croissants or biscuits to muffins or breads, all these products have one characteristic in common: they are highly sensitive to oxygen, humidity and handling. This is why the packaging process becomes a critical element to ensure that they reach the end consumer in optimal conditions. In this article we will explore how flow pack packaging helps maintaining the quality of baked goods.
The Flow Pack in the bakery industry
The flow pack is a horizontal packaging system that forms, fills and seals the package in a single production line. This method is characterized by its high speed, versatility and ability to provide an airtight seal, ideal for sensitive products such as baked goods.
In the bakery sector, the flow pack has become the preferred option for packaging products such as muffins, cookies, cookies, bread, croissants, doughnuts and gluten-free products, among others. Its ability to adapt to different sizes and shapes, combined with a sealing system that can incorporate modified atmosphere (MAP), makes it ideal for maintaining the balance between shelf life and presentation.
In addition, with advances in automation and intelligent control, modern flow pack machines such as Synchropack’s allow seamless integration with high-performance production lines, maintaining precise control over parameters such as temperature, speed, and sealing pressure.
Benefits of Flow Pack packaging for baked goods
Implementing a flow pack solution in a bakery production line offers multiple advantages from a technical point of view:
- Shelf life extension thanks to hermetic sealing and the possibility of integrating MAP.
- Versatility of formats: with a single machine it is possible to wrap different types of products and formats.
- Attractive presentation thanks to film customization.
- High productivity thanks to its design prepared to operate at high speeds.
- Integration in automated lines.
Elements to consider when Flow Pack packaging baked goods
Packaging baked goods presents specific challenges due to their structure, moisture content and sensitivity to oxygen. The following are the main factors to consider when implementing flow pack in this category:
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Selecting the right film
The type of film is critical. Materials must have good barrier properties to prevent oxygen and moisture ingress. For crispy products such as cookies or baked snacks, it is key to keep them dry, while for tender or filled products, moisture loss should be avoided.
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Sealing system design
Seals must be hermetic, resistant and compatible with the type of product and film used. In delicate products, excessive pressure or temperature can deform the food. Therefore, machines must offer precise control of these parameters.
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Modified atmosphere (MAP)
Many baked goods benefit from the use of modified atmosphere, where the air inside the package is replaced with gases such as nitrogen or carbon dioxide. This reduces oxidation and microbial growth, significantly extending shelf life without the need for preservatives.
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Careful handling
Baked goods can be fragile, especially if they have toppings, glazes or fillings. Therefore, it is essential to have automatic feeding systems that avoid excessive contact or vibrations.
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Type of presentation
The packaging design should consider whether the product will be presented individually, in family packs or in specific groupings for the distribution channel (retail, vending, food service). This affects not only the type of film and dimensions, but also the configuration of the packaging line and the subsequent logistics.
Individual or grouped formats: impact on conservation
When designing the ideal packaging in a flow pack line, one of the most strategic decisions is whether to present the product individually or in a grouped format. Beyond the question of aesthetics or volume, this choice has a direct impact on shelf life, logistics and even how the consumer relates to the product.
Individual packaging: designed for today’s pace
Individual wrappers are perfectly suited to today’s fast-paced, dynamic and often on-the-go lifestyles. They are the preferred choice for snacks, vending products or on-the-go consumption. Each unit travels protected on its own, ensuring freshness, hygiene and better preservation, especially in demanding environments such as transport or vending.
In addition, they offer key functional advantages: they enable precise product dosing, favor portion control and improve the end-user experience, who can open and consume only what they need, without compromising the rest of the batch.
Group packaging: efficiency and convenience for home and retail
On the other hand, group packs (especially when targeting the retail channel or consumers buying as a family) offer clear benefits in logistical and commercial terms. Grouping several units in a single package reduces the use of materials, improves transport efficiency and facilitates promotions such as savings packs or “2-for-1” products.
However, this format requires greater precision in the packaging process: it is essential to ensure the stability of all the products inside and to guarantee a homogeneous seal. Often, it is even combined with individual flow packs within the group pack, thus offering double protection and greater versatility at the point of sale.
At Synchropack, we understand that the market is not static and that each product and each brand has different needs. That’s why we develop flexible flow pack solutions that allow for easy switching between single and multipack formats within the same production line. This enables our customers to adapt quickly to consumer demands and changes in the distribution channel, without compromising efficiency or quality.
