The Importance of Moisture Control in Plant-Based Packaging

Plant-based packaging is good for the planet but more sensitive to moisture than traditional plastics. The right approach to moisture control in plant-based packaging keeps food fresh, prevents packaging failure, and helps brands avoid costly spoilage and returns.

The Rise of Plant-Based Packaging in Food

Plant-based food packaging has gained rapid traction as consumers demand eco-friendly and compostable options. Brands are switching to materials like PLA (polylactic acid), paper-based laminates, and molded fiber trays to reduce their environmental impact. These innovations help reduce reliance on petroleum-based plastics and align with corporate sustainability goals.

But with innovation comes new challenges. These natural materials behave differently than plastics, especially when exposed to humidity. Without proper plant-based food packaging protection, companies risk losing more product to spoilage, damaging their reputation, and wasting the sustainability gains they worked so hard to achieve.

Why Moisture Is a Bigger Issue for Plant-Based Packaging

The very features that make plant-based packaging appealing—renewable, compostable, breathable—also make it more permeable. Moisture passes through many plant-based films and trays at a faster rate than through conventional plastics. That means humidity in a warehouse, condensation in a truck, or temperature swings on a retail shelf can:

• Soften and warp packaging: Paper-based trays can lose rigidity when exposed to moisture.
• Reduce shelf life: Higher internal humidity accelerates mold growth or staling.
• Cause barrier failure: Once coatings break down, oxygen and moisture ingress increase sharply.

These risks make moisture control in plant-based packaging not optional but essential. It’s the difference between delivering a premium, eco-friendly experience and losing credibility with retailers and consumers.

How Moisture Threatens Food Quality

Moisture exposure doesn’t just impact the package, it directly affects the food inside. When relative humidity inside a pack rises, water activity in the product also increases. This can lead to:

• Texture changes: Crunchy snacks turn soft, powders clump, and confections bloom.
• Microbial growth: Higher water activity levels support mold and bacteria.
• Flavor loss: Moisture can trigger rancidity in nuts, seeds, and high-fat products.

For plant-based packs, which already have less of a moisture barrier, these changes can happen faster than teams expect. Failing to manage humidity risks spoilage, consumer complaints, and expensive product write-offs.

The Role of Desiccants in Protecting Plant-Based Packaging

This is where desiccants for sustainable packaging come into play. Desiccants are materials designed to absorb water vapor from the surrounding environment. When added to plant-based packaging, they:

• Maintain a stable microclimate inside the pack.
• Reduce condensation risk during temperature swings.
• Help extend shelf life by keeping relative humidity in a safe range.

Silica gel, clay, and molecular sieve are the most common desiccant types used in food packaging. Each offers unique absorption rates and performance characteristics, allowing packaging engineers to select the right material for their product and route. The result is more consistent quality from production through retail display.

Best Practices for Pairing Desiccants With Plant-Based Packaging

Getting the most from moisture control in plant-based packaging requires careful planning. Here are some key considerations:

1: Size for the Real Moisture Load

Because plant-based films are more permeable, you may need a slightly larger packet than you would for a plastic pack. Use headspace measurements, product water activity data, and transit climate information to calculate capacity.

2: Optimize Placement

Place the desiccant where it has good airflow within the pack but away from sealing jaws. Good placement ensures maximum contact with the headspace air and minimizes the chance of packet damage.

3: Store Packets Properly

Keep packets in sealed bins at low humidity before use. If they saturate on the line, they won’t protect the product.

4: Validate Through Testing

Run shelf-life studies and humidity logging with actual routes. Data-backed validation ensures your program works under real conditions.

Following these steps creates a robust system for plant-based food packaging protection and avoids last-minute surprises at the retail level.

Food Safety and Compliance Considerations

Packaging teams must ensure every component meets applicable safety standards.

Meet Regulatory Standards

Choose desiccants manufactured with food-contact safe materials that comply with FDA (21 CFR) regulations in the United States and EU food-contact directives internationally. Global brands should also verify compatibility with standards in Canada, China, and other key markets. Documentation such as Certificates of Compliance and Type III Drug Master Files (DMFs) provide assurance that the product meets stringent requirements for purity and safety.

Prioritize Clear Labeling and Consumer Education

Packets should always carry highly visible “Do Not Eat” warnings or pictograms, even if the desiccant is in a sealed plant-based package. This prevents misuse, reduces liability, and ensures compliance with labeling guidelines. For consumer-facing brands, consider QR codes or website links that explain why the packet is in the package and why it’s safe as long as it isn’t ingested.

Safe Chemistry and Indicators

Select desiccant chemistries appropriate for food environments. Silica gel and clay are widely accepted for direct food contact, while molecular sieve is ideal for products that require very low humidity. If your process includes saturation indicators, confirm that dyes are cobalt-free and approved for food-contact scenarios, or opt for non-indicator packets for direct-contact applications.

Thermal and Process Compatibility

Sustainable packaging often runs through hot-fill or retort processes. Verify that the desiccant packet’s film and adhesive system can tolerate your line temperatures without leaking or degrading. Heat stability ensures that the desiccant stays effective and uncontaminated throughout production and shipping.

Why Compliance Matters

Non-compliant packaging can trigger recalls, fines, and reputational damage. Maintaining rigorous compliance protects consumers, minimizes regulatory risk, and gives retailers confidence in your product’s safety. A compliant moisture-control program also supports ESG reporting, since it reduces waste by keeping more product shelf-stable until purchase.

Key Takeaways

The rise of plant-based materials has brought new challenges in maintaining product integrity. Moisture control in plant-based packaging is now a core quality consideration for food manufacturers. By using desiccants for sustainable packaging, companies can:

• Protect the physical integrity of eco-friendly packs.
• Prevent microbial growth, texture loss, and flavor changes.
• Deliver a consistent consumer experience that builds loyalty.

Investing in plant-based food packaging protection pays off in fewer complaints, longer shelf life, and stronger retailer relationships.

Keep Your Products Fresh and Packaging Strong

Plant-based packaging should deliver sustainability without sacrificing quality. Reach out to Multisorb’s team to explore desiccant options, capacity sizing, and validation programs that keep your products fresh and your packaging strong, no matter where they travel.