Plastic Packaging – Impacts & Solutions for the Seafood Industry

The Vietnamese seafood sector is one of the pillars of the country’s export economy, reaching a turnover of over USD 9 billion in 2023 (VASEP, 2024). However, due to the high water content, perishability, and environmental sensitivity of seafood products, both fresh and frozen seafood require packaging not only for containment but also for preservation, extended shelf life, food safety, and maintaining sensory quality.

Among the available options, molded PET and PP plastic packaging has emerged as an effective solution, while EPS/foam is gradually being phased out. This shift is driven not only by technical requirements but also by green consumer trends, international regulations, and sustainability objectives.

This article provides a comprehensive analysis of the impact of plastic packaging on seafood preservation—from technical aspects, logistics, and food safety, to market trends in 2025—offering clear insights for Vietnamese businesses developing packaging strategies.

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1. The Role of Packaging in Seafood Preservation

The seafood industry has unique characteristics compared to many other food sectors: fresh and frozen products contain high water content, making them highly susceptible to spoilage due to microorganisms and oxidation. With Vietnam’s seafood exports exceeding USD 9 billion in 2023 (VASEP, 2024), packaging has become a key factor in maintaining quality, reducing losses, and adding value along the supply chain.

1.1. Preventing Microbial Spoilage

Seafood provides an ideal environment for bacterial growth, especially when stored at 0–4°C. Plastic packaging can form a physical and gas barrier that reduces microbial infiltration from the external environment. When combined with Modified Atmosphere Packaging (MAP) technology, packaging further helps reduce oxygen concentration, slow lipid oxidation, and limit aerobic bacterial growth.

1.2. Maintaining Freshness and Appearance

One of the most direct factors influencing customer purchase decisions is the appearance of the product. Transparent plastic packaging, particularly anti-fog PET/PP, allows customers to clearly observe the color, texture, and freshness of fish and shrimp without obstruction from condensation. This builds trust and enhances the shopping experience.

1.3. Extending Shelf Life

According to FAO (2021), using plastic packaging in combination with MAP can extend the shelf life of fish fillets by 5–7 days compared to traditional packaging (FAO Report). This not only reduces food waste but also increases flexibility in the logistics chain, particularly for long-distance exports to the EU or USA.

1.4. Reducing Losses in Logistics

Exported seafood is often transported in refrigerated containers for extended periods (2–6 weeks). Molded PET/PP packaging helps products be stacked neatly, reducing collisions, breakage, and leakage. This lowers spoilage rates and saves costs for businesses.

1.5. Meeting International Safety Standards

Major import markets such as the EU, USA, and Japan require food-contact packaging to comply with FDA, HACCP, ISO 22000, and EU 10/2011 standards. PET and PP packaging easily meets these requirements due to their safety characteristics and comprehensive technical documentation. Using certified plastic trays not only facilitates export but also enhances the reputation of Vietnamese businesses.

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2. Comparison of PET, PP, and EPS in Seafood Preservation

In the seafood industry, choosing the right packaging material directly affects product quality and the ability to penetrate export markets. Currently, the three most common plastics are PET (Polyethylene Terephthalate), PP (Polypropylene), and EPS (Expanded Polystyrene). Each type has its own advantages and limitations.

2.1. PET – Optimal for Display and Premium Exports

PET offers near-glass transparency, allowing consumers to clearly see the color and structure of salmon, sashimi, or lobster. This is a critical factor in high-end supermarkets and retail chains in Japan and South Korea, where purchase decisions are made within seconds of visual inspection.

Other advantages of PET include high mechanical strength, making it less prone to cracking during long-distance transport. Additionally, PET has a global recycling infrastructure, making it easier to meet the “green” requirements of the EU and USA. However, PET has low heat resistance, making it unsuitable for products that require heating.

2.2. PP – Flexible for Freezing and Heating

PP stands out for its ability to withstand temperatures up to 120°C, allowing direct microwave heating while remaining non-brittle under freezing conditions. This makes it an optimal choice for fish fillet trays, frozen shrimp, and processed seafood products.

Another advantage of PP is compatibility with topseal and skin pack technologies, providing airtight packaging and enabling MAP to extend shelf life. In terms of cost, PP is cheaper than PET, suitable for large-scale production in Vietnam and other Asian markets.

2.3. EPS – Cheap but Outdated and Risky

EPS was once popular due to its low cost, light weight, and good insulation, commonly used for inexpensive fish or shrimp trays in traditional markets. However, EPS has several significant limitations:

Brittle and fragile, prone to leakage during transport.
Difficult to recycle, with collection costs exceeding recovery value.
Health risks: Styrene in PS/EPS is classified as Group 2B by IARC – potentially carcinogenic to humans (IARC Monographs).

Consequently, the EU banned single-use EPS containers from 2021 under the Single-Use Plastics Directive (European Commission, 2021). Canada also included EPS in its list of banned plastics from 2022.

2.4. Overall Comparison

PET: Suitable for premium seafood, emphasizes display, exports to EU/Japan.
PP: Suitable for frozen and processed seafood, long-distance exports.
EPS: Limited to low-cost domestic segments but will soon be phased out.

According to Euromonitor (2024), PET and PP in Vietnam’s food packaging market grew at an average of 12% per year during 2020–2025, while EPS declined continuously.

Image Source: Euromonitor International; leads the world in data analytics – Euromonitor.com

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3. Advanced Plastic Packaging Technologies for Seafood

As market demand grows, plastic packaging for seafood goes beyond simply “holding” the product. Modern technologies are integrated to maintain freshness, extend shelf life, and enhance competitiveness. Below are key packaging technologies applied in the industry:

3.1. Anti-fog

During cold storage, seafood often releases condensation on the packaging surface, causing fog and obscuring the product. Anti-fog technology adds additives to the plastic or applies a coating, ensuring water spreads evenly as a transparent thin layer instead of forming droplets. This keeps the product clearly visible, enhancing its appeal in stores.
According to the FDA (2021), anti-fog additives are classified as a Food Contact Substance, safe for direct contact with food (FDA.gov).

3.2. Topseal & Skin Pack

These two technologies have become standard in premium seafood packaging. Topseal uses a film to seal the tray, reducing liquid leakage, allowing easy stacking, and optimizing container space. Skin pack creates a film that tightly conforms to the product, maintaining its natural structure and limiting microbial growth.
Research from ScienceDirect (2022) shows that skin pack packaging combined with MAP can extend salmon shelf life by 30% compared to conventional packaging (ScienceDirect).

3.3. Co-extrusion (Multi-layer Extrusion)

Multi-layer extrusion technology allows PET/PP to be combined with an EVOH barrier layer, providing strong protection against oxidation. This extends seafood shelf life, especially useful for long-distance exports to the EU or US.

3.4. Smart Packaging

A growing trend is integrating freshness indicators or gas indicators on trays or films. These labels change color as seafood begins to lose freshness, allowing consumers and retailers to monitor quality easily. While not yet widespread in Vietnam, this technology is being tested in Japan and Europe.

3.5. Integration of Recycled and Bio-based Materials

To comply with the EU Plastic Tax (2025, minimum 25% recycled content), many manufacturers are experimenting with rPET, rPP, and even blending bio-based plastics into production. This not only reduces carbon emissions but also provides a competitive advantage for exporters.

4. Impact on Logistics and Export

Vietnam’s seafood industry heavily relies on exports, accounting for over 80% of total production. Therefore, plastic packaging not only affects domestic preservation but also directly influences logistics efficiency and international competitiveness.

4.1. Reducing Transportation Risks

During long international shipments in refrigerated containers, packaging must withstand impacts, vibrations, and temperature fluctuations. Molded PET and PP trays have high mechanical strength, minimizing breakage and leakage. This reduces product losses and saves costs on claims and returns.

4.2. Optimizing Container Space

Compared to bulky EPS boxes, molded PET/PP trays allow uniform stacking and consistent sizing, maximizing container capacity. This helps businesses lower logistics costs per unit, an important factor in the thin-margin seafood industry.

4.3. Compliance with International Standards

Major import markets such as the EU, US, and Japan require packaging to meet safety certifications: FDA (US), EU 10/2011, HACCP, and ISO 22000. PET/PP packaging easily meets these standards with complete technical documentation, giving Vietnamese exporters an advantage in contract negotiations.

4.4. Enhancing Importer Confidence

International distributors increasingly view plastic packaging as a measure of a company’s capability. Certified PET/PP trays with transparent material information and proper documentation reinforce a professional and sustainable image. Conversely, using cheap EPS packaging may raise concerns about reliability and long-term compliance.

4.5. Case Study from Vietnamese Companies

According to VASEP (2024), the rate of Vietnamese seafood shipments returned due to packaging and labeling violations decreased by 15% after many companies switched from EPS to PET/PP trays (VASEP Report). This demonstrates that modern plastic packaging not only improves preservation quality but also directly enhances export efficiency.

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5. Trends and Challenges Toward 2025

Vietnam’s seafood industry is undergoing a significant transformation. Plastic packaging is not only a technical necessity but also a key component of sustainable development and international integration strategies. By 2025, the main trends and challenges are projected as follows:

5.1. Key Trends

PET and rPET leading the market: With high recyclability and transparency, PET—especially rPET—will dominate premium seafood packaging. The EU mandates a minimum of 25% recycled plastic in packaging by 2025, driving businesses to adopt rPET (European Commission, 2021).
PP packaging in frozen seafood: With excellent heat and cold resistance and compatibility with skin pack technology, PP remains the optimal choice for fillets, shrimp, and ready-to-heat products.
Smart packaging: Freshness indicators and gas indicators are increasingly integrated into PET/PP trays, helping supermarkets and consumers monitor product quality.
Rapid reduction of EPS/foam: With bans on single-use EPS in the EU, Canada, and many U.S. states, EPS is rapidly being removed from modern retail supply chains.

5.2. Key Challenges

High technology investment costs: Deploying topseal, skin pack, or co-extrusion production lines requires significant capital, which can be a barrier for small and medium enterprises.
Strict legal compliance: Exporting to the EU/US requires full documentation of packaging certifications (FDA, EU 10/2011, HACCP, ISO 22000). Companies without adequate testing capabilities may struggle to prove compliance.
Limited recycling infrastructure in Vietnam: Although PET/PP packaging is recyclable, actual collection rates are low, which could affect compliance with EU Plastic Tax regulations.
Global competition: Competitors from Thailand, India, and Indonesia are heavily investing in sustainable packaging, increasing pressure on Vietnamese businesses.

5.3. Recommended Actions
To overcome these challenges, Vietnamese companies should:

Prioritize investment in advanced plastic packaging technologies (topseal, skin pack, anti-fog).
Transparently publish international certifications on websites and catalogs.
Establish partnerships with rPET/rPP suppliers to meet Plastic Tax requirements.
Leverage trade agreements (EVFTA, CPTPP) to expand export markets.

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Further Reading: Single Use Plastics Directive Implementation Assessment Report – PowerPoint Presentation

Conclusion

Plastic packaging has played, continues to play, and will remain a central role in preserving and enhancing the value of Vietnamese seafood. From maintaining freshness and preventing microbial spoilage to supporting logistics and meeting export standards, PET and PP solutions clearly outperform traditional EPS. Plastic packaging is not just a storage tool—it is a competitive strategy that helps Vietnamese businesses integrate into a global supply chain that is increasingly stringent on safety and environmental standards.

Looking toward 2025, with Plastic Tax, EPR, and sustainable development commitments becoming the new “common rules,” businesses must proactively shift to PET/rPET and PP packaging while investing in technologies such as anti-fog, skin pack, and topseal. Only by doing so can Vietnam’s seafood maintain its reputation, expand its markets, and advance further on the global export map.

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