HIGH PRESSURE PROCESSING (HPP) & PACKAGING

What you need to know when selecting packaging for HPP applications.

WHAT IS HIGH PRESSURE PROCESSING (HPP)?

High Pressure Processing (HPP) is an advanced, non-thermal preservation method used in food and beverage packaging. Instead of heat, products are subjected to extremely high pressure, typically up to 6,000 bar, to eliminate harmful microorganisms while maintaining flavour, texture and nutritional value.

Unlike traditional methods, HPP is applied after the product has been sealed in its final packaging, making packaging performance critical to success.

WHY PACKAGING MATTERS IN HPP

During HPP, sealed packs are placed into a water-filled chamber and subjected to uniform pressure from all directions.

As a result, packaging will:

Compress by up to 15% in volume
Be fully submerged in water
Return to its original shape once pressure is released

Your packaging must be designed to withstand this entire cycle without compromising integrity, appearance or shelf life.

KEY PACKAGING REQUIREMENTS FOR HPP

1. Flexibility and recovery

Packaging must flex under pressure and return to its original form without damage.

Best suited formats:

Flexible pouches
Semi-rigid bottles (for example, PET, HDPE)
Trays with flexible lidding films

Rigid materials such as glass or metal are not suitable, as they cannot accommodate the compression involved

2. Seal strength and integrity

Seals are the most common failure point in HPP.

To ensure performance, packaging must:

Maintain strong, consistent heat seals
Resist stress at edges and corners
Prevent micro leaks during compression

Even minor weaknesses can lead to pack failure post processing.

3. Material structure

HPP packaging typically relies on multi-layer materials to balance flexibility, strength and barrier performance.

Common structures include:

PET / PE
PA (Nylon) / PE
EVOH based barrier films

These materials provide:

Resistance to pressure and puncture
Structural stability during processing
Protection against oxygen and moisture ingress

4. Barrier performance

HPP extends microbiological shelf life, but packaging must protect product quality.

Key considerations:

Oxygen barrier for sensitive products such as juices or sauces
Moisture control for fresh and prepared foods

Effective barrier properties ensure the product stays fresher for longer

5. Pack design and shape

Simple, well-balanced designs perform best.

Recommended:

Rounded corners
Even wall thickness
Symmetrical shapes

Avoid complex geometries or sharp edges, which can create stress points during compression.

6. Headspace control

Air behaves differently under pressure and can affect pack stability.

To avoid deformation:

Minimise headspace wherever possible
Consider vacuum or controlled fill systems

This helps maintain pack shape and appearance after processing

IN SUMMARY

When selecting packaging for High Pressure Processing, success depends on:

Flexible materials that recover after compression
Strong, reliable seals
Multi-layer structures for durability and barrier performance
Thoughtful pack design and headspace control
Proven HPP validation and testing

READY TO GET STARTED?

If you are exploring High Pressure Processing for your products, our team can help you select packaging that performs from production through to shelf.