High barrier without aluminium foil: coatings, metallising and EVOH

Aluminium foil is the gold standard for barrier against oxygen, moisture and light. It also makes a pack heavy, opaque and impossible to recycle in plastic streams. For many products, foil gives more barrier than they need. These are the main alternatives.

Metallised films

A thin layer of aluminium is vacuum-deposited onto BOPP, PET or PE film. Metallised films give good light and moisture barrier at a fraction of foil's metal content, and they are already common in snacks and confectionery. Metallised BOPP fits well in all-PP structures.

Transparent oxide coatings (AlOx and SiOx)

Aluminium oxide or silicon oxide coatings, only nanometres thick, give a high oxygen barrier while keeping the film clear. They suit products where the customer wants to see the contents, and they work with mono-material designs. They need careful handling, because cracking from flexing can reduce barrier.

EVOH layers

Ethylene vinyl alcohol is an excellent oxygen barrier, used as a thin layer inside co-extruded PE or PP films. Kept within recycling guideline limits, EVOH lets all-PE and all-PP packs protect oxygen-sensitive products such as coffee, cheese or ready meals. It is sensitive to humidity, so it is always sandwiched between moisture-resistant layers.

Barrier coatings and lacquers

Water-based barrier coatings can be applied on press to improve oxygen or grease resistance on films and papers. They are a useful tool for paper-based packs.

Choosing the right option

Always confirm shelf life with real storage tests on the new structure.

How we can help

We can compare barrier options for your product and run shelf-life trials. Ask our team.