Food Safety Considerations for Secondary Packaging 

What is secondary packaging? 

Secondary packaging is the outer carton, that holds and protects the primary packaging item. For example, a display box holding packs of muesli bars for purchase from a retail shelf, or a shipping mailer box containing protein powder purchased through an eCommerce store  

It is a crucial element of both the display and transit of goods for a business as it helps with the safe storage and handling of a product and can be the difference between a successful order and a costly recall. 

It is important for food and beverage businesses to have some practical steps to ensure their secondary packaging keeps food safe from production to shelf and into customers’ homes. 

In this guide we cover key regulatory checks, safe material choices, hygiene and handling practices, testing and supplier auditing, plus quick actions you can take now to lower risk and increase confidence in your food packaging. 

Why secondary packaging matters for food safety 

Primary packaging is the obvious line of defence for food safety, but secondary packaging plays a crucial supporting role. It protects primary packs from crushing, contamination and moisture during storage and transport. If secondary packaging fails, the primary pack and the product inside can be compromised, leading to customer complaints, product spoilage, regulatory scrutiny or even recalls. 

Thinking about secondary packaging early reduces the chance of contamination, helps maintain temperature and humidity control during transit and makes handling safer for logistics and retail teams. 

Regulatory and compliance basics 

Food brands cannot assume all packaging materials are equal. Regulatory expectations vary by market, but the core principle is the same: any material that could reasonably contact food must be demonstrably safe. 

Know the relevant standards for your markets. In Australia Food Standards Australia New Zealand (FSANZ) provides guidance on food contact materials. If you export, check EU and US rules where applicable. Always ask suppliers for material declarations, MSDS and any migration test results. Where appropriate, require supplier audits or third-party testing to prove compliance. 

Documentation to request from suppliers includes supplier declarations of suitability for food contact, MSDS, certificates of compliance and audit or test reports. These documents protect you and give you evidence to show regulators or customers if questions arise.

Choosing materials for safe secondary packaging 

Not all materials perform the same when it comes to protecting food. Secondary packaging needs to manage moisture, prevent physical damage and avoid chemical migration or odour transfer. Consider the following when selecting materials. 

Corrugated board with food safe liners works well for many chilled and ambient products. Kraft mailers can be used for many dry goods but consider an inner sealed liner or pouch for greasy or high moisture items. Grease resistant board is essential for products like bakery items or high oil foods. For fragile or high value food, moulded pulp or custom foam inserts can provide protection without loose filler. 

Always verify inks, adhesives and coatings. Some inks and adhesives contain substances unsuited to food environments. Request supplier confirmation that inks and adhesives used in production are food grade or do not pose migration risks. If in doubt, specify food safe inks and adhesives and document the supplier assurance. 

Design and handling to reduce contamination risk 

Good packaging design reduces handling and contamination risk. Seek sealed or tamper evident closures for products that must remain sterile until opening. Talk to your supplier about what moisture control features they can add if you have chilled and frozen items that need transporting, such as ventilation options for products that release moisture or gases, and using packing designs that do not trap crumbs or liquid where they can accumulate.  

Production hygiene matters, and a good packaging supplier with experience in food and beverage will use a clean and segregated production line for food versus non-food items. They will keep records showing regular equipment sanitation, cleaning schedules and traceable batch codes. 

Transport and storage are part of the design brief. Communicate stacking limits, temperature ranges and handling instructions on the carton to minimise damage during logistics. For temperature sensitive products, include temperature indicators or data loggers in pilot runs to verify conditions through the cold chain. 

 Testing, validation and supplier auditing 

Testing is the proof point. Common tests for secondary packaging include migration testing for inks and adhesives where food contact is possible, microbial swabs for contact surfaces and transport simulation tests such as drop, vibration and compression testing. 

Start with a risk-based approach. High risk products such as chilled, frozen or high fat items should undergo more rigorous validation. Request third party lab reports when migration or contamination is a concern and include routine supplier audits in your procurement process to ensure ongoing compliance. 

Supplier auditing should check production hygiene, raw material sourcing, documentation and traceability systems. Keep a simple audit checklist to standardise supplier reviews and capture evidence you can refer to if quality issues appear. 

Labelling, traceability and consumer guidance 

Clear labelling helps everyone handle your product correctly. Include storage instructions, handling notes and best before or lot information on secondary packaging or the included packing slip. Tamper evident features and batch codes improve traceability and make recalls or investigations faster and more contained. 

Communicate disposal and recycling instructions clearly, especially if the pack uses liners or mixed materials. Where sustainable choices add complexity, explain what to remove and how to dispose of each component so consumers can recycle correctly without compromising food safety.

Practical examples and use cases 

Mail order chilled meals 

Secondary packaging should include an insulated liner or pouch and secure closures. Add gel packs or dry ice as needed and use temperature indicators during pilots to confirm safe transit windows. 

Bakery deliveries 

Grease resistant corrugated cartons or kraft mailers with an inner grease proof liner help protect both product and pack. Design for gentle stacking and avoid designs that trap crumbs.