Pillow bag packaging is the dominant format in the snacks category, particularly for chips, due to its cost-efficient production, lightweight structure, and superior barrier properties against moisture, oxygen, and light. Despite these advantages, the lack of effective reclosure mechanisms poses a critical challenge in maintaining product quality upon opening the packaging. This study addresses this limitation by engineering innovative and cost-effective reclosure systems optimized for pillow bag applications. The research encompassed a comprehensive market analysis of existing reclosure technologies, consumer-driven ideation from social media insights, and the adaptation of solutions from various product categories. A diverse range of reclosure concepts were ideated with a focus on usability, manufacturability, and material efficiency. Prototypes of selected designs—Origami Fold, Fold & Tie, and Twist & Tie—were fabricated and subjected to performance evaluation testing. Barrier properties were quantified using the Gravimetric Method under standard and accelerated storage conditions, while Finite Element Analysis (FEA) was employed to investigate shape optimization aimed at reducing stress concentration and preventing progressive tearing in such materials. The selected systems demonstrated significant improvements in barrier performance over conventional open chip packaging, validating their applicability and effectiveness. This research provides a novel, user-centric, and sustainable solution to an enduring challenge in flexible food packaging, advancing both consumer convenience and the industry's sustainability objectives.
Read
