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TODAY WHEN consumers tear open a new bag of potato chips, they do so with confidence that the chips inside will be crisp, fresh and flavorful. They have come to recognize the shiny, metallic lining inside chip bags as a sign of quality and freshness, but it wasn't too long ago that potato chip packaging provided only minimal protection. And it has only been in the past 50 years that packaging film advances have made it possible to expand potato chip production beyond small regional companies to national brands. In more recent times, packaging material suppliers and leading companies such as Hostess, Frito Lay and Humpty Dumpty began working together to develop the chip bag that has come to be the industry standard throughout this country, and then in the United States. Packaging innovations developed over the past 20 years or so have taken the potato chip package from the once familiar foil/paper laminate to the metallized oriented polypropylene bag in use today. As it turns out, the chip bag is an evolving structure with new adaptations underway that will take it well into the next century. Evolution from the traditional foil/paper bag to today's thinner, more protective metallized oriented polypropylene (OPP) structure has taken less than a couple of decades with the first commercial sales of the metallized OPP structure by Mobil in 1984. Chip manufacturers had previously used foil along with paper for the bags because of the excellent light barrier of foil. Chip producers learned early on that light accelerates the spoiling process. That's because the UV light serves as a catalyst, which causes oxidation of the fat in the chips and produces rancidity. Without a light barrier, potato chips can become rancid in a matter of hours while adding a metal layer can extend the shelf life to several weeks. Chip producers found that using foil solved the light problem, but created others. One problem was poor sealing characteristics and the other was handling problems associated with the foil. In many cases, seals on the foil/paper bags failed because the nature of the paper made consistency of seal quality problematic. Although the foil itself offered an excellent moisture barrier, pinholes resulting from processing allowed moisture through, eliminating the value of foil as a barrier. To address these issues, manufacturers searched for a material that would not only protect their products, but look good on the shelf. Keeping Out the Light Metallized OPP film, first developed in the early 1980s, eliminated these problems and proved to be just the ticket. Chip manufacturers saw the new films as delivering the double benefit of graphic quality along with light barrier. Because it was possible to obtain better printed reproduction with the new metallized film than with the foil, the visual appeal of potato chip bags improved significantly, adding to their shelf appeal. By 1984, other Canadian potato chip manufacturers were using metallized film and the amount of metallized film sold amounted to more than two-million lbs. Metallized film was ready for the next step. Chip manufacturers, converters and film companies then turned their attention to improving the quality of seals. Modifications to packaging equipment and structural changes each played a role in creating durable bags. Under its Race-Track Sealers program, Mobil technicians modified packaging machines for customers throughout Canada to help them make the transition from paper/foil bags to plastics. The modified equipment formed consistently better back seals. To improve the structure of the film itself, converters played an important part in enhancing the extrusion lamination process. The result was a substrate that offered converters a wider operating window than was available previously. This new substrate allowed converters to run faster while producing a robust structure and good seals. And, the cooperation with converters went a long way toward eliminating crazing, another problem associated with metallized film. Crazing resulted in a rainbow appearance and the possibility of leaks. In 1985, Mobil developed a film for metallization that was both craze-resistant and provided a leak proof seal when metallized. Efforts by major snack food producers to improve their products while cutting costs resulted in several innovations that subsequently have become standard operating procedures. A major revolution was the change in relationships, turning vendors into partners so that suppliers would have a reason to invest in their customers' businesses. After its film for metallizing was a marketplace success, Mobil worked with metallizers, converters and chip manufacturers on joint programs to create total cost solutions. These programs included organizational and scheduling support to deliver shared savings. In fact, continuing partnerships with converters and end-users have shaped the way Mobil works in the packaging industry. As a result of product improvements and the success of total cost programs, many chip producers supported metallized OPP as the preferred potato chip bag material. After the Canadian market adopted the metallized OPP bag, snack food manufacturers in the United States took notice. They recognized the solution to many of the problems they had experienced with potato chip packaging and the metallized OPP structure traveled south, quickly becoming the bag of choice in the United States, replacing glassine- and foil-containing structures. Although consumers noticed the change from foil/paper bags to the metallized OPP structure, they did not notice the other changes, such as the machinery improvements that produced better seals. And, while they may be unaware of the advances in technology resulting from the use of today's high barrier films and gas-flush processing, they do recognize -- and prefer -- the first-day fresh flavor now available. Market research confirms this statement, demonstrating category growth and share gain for gas-flushed chips. Gas flushing keeps oxygen from coming into contact with the chips by replacing oxygen-containing ambient air with nitrogen, a process requiring a high-oxygen barrier film to keep oxygen out of the package. It's no secret that consumer tastes are changing and the growing variety of chip flavors reflects their changes. Over the years chip producers have introduced barbecue, sour cream and onion, and salt and vinegar flavored products. Today consumer tastes -- influenced by the spicy seasonings found in warmer, vacation-destination climates -- are moving toward salsa, curry and jalapeno-based flavors. Chip manufacturers rushing to meet the demand have shown themselves early adopters of new flavoring combinations. And, as they introduce more spicy and savory offerings, they have a need for packages that can avoid flavor scalping to retain the exotic flavors. Coated films provide the answer chip manufacturers are seeking. They may, in fact, be the next trend in chip packaging because they promise the ability to prevent flavor loss or the scalping of flavors by the film. ability to prevent flavor loss or the scalping of flavors by the film.