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Everything about
aluminium
Everything about
aluminium
At PouchDirect, we often get questions like: “Does this pouch contain aluminium?” or “Is METPET the same protection as aluminium?” Understandable, since terms like aluminium and metallized PET (METPET) are often used interchangeably. On this page, we explain exactly what aluminium is, what it does in a pouch, and whether you really need it for your product.
At PouchDirect, we often get questions like: “Does this pouch contain aluminium?” or “Is METPET the same protection as aluminium?” Understandable, since terms like aluminium and metallized PET (METPET) are often used interchangeably. On this page, we explain exactly what aluminium is, what it does in a pouch, and whether you really need it for your product.
What is aluminium?
Aluminium is a light, metal-like material that's often used in flexible packaging as a thin foil layer between other film layers. This layer is completely lightproof, oxygen-proof and offers an extremely strong barrier against moisture and gases. That makes it one of the most powerful barrier materials on the market.
What is aluminium used for?
Products that are very sensitive to light, air or moisture benefit from an aluminium layer. Think of:
• Powders like protein powder or instant drinks
• Pharmaceutical or chemical substances
• Pet food with a long shelf life
Why add aluminium to a pouch?
An aluminium layer adds extra protection. It prevents oxidation, extends shelf life and protects aromas or active ingredients from breaking down. Especially for products that are sensitive to oxygen or UV light, aluminium is the go-to solution for maximum freshness.
Aluminium vs METPET
What’s the difference?
Aluminium and METPET often get mixed up, but there’s a real difference in both material and application. At PouchDirect, we use metallized PET (METPET) for a reason.
METPET is a PET film with an ultra-thin metal coating. This layer provides a very high barrier against oxygen, light and moisture. For the vast majority of our customers – around 99% – that’s more than enough to keep products fresh for a long time. Think of coffee, tea, spices, pet food and powders: all of these stay perfectly fresh in METPET packaging.
A full aluminium layer can technically offer slightly more protection, but in most cases, it’s not necessary. It also requires more material, making it heavier and less sustainable. At a time when reducing material use is more important than ever, METPET is often the smarter choice – both in performance and sustainability.
In short: METPET offers excellent protection and is the perfect balance between barrier and material efficiency.
| Feature | METPET (metallized PET) | Aluminium foil |
| Oxygen barrier | Very high | Ultimate (a bit higher) |
| Light barrier | Very high | 100% lightproof |
| Moisture barrier | High | Very high |
| Shelf life | Suitable for long-term use | Maximum protection |
| Thickness & weight | Thin & lightweight | Thicker & heavier |
| Sustainability & recycling | Better (less material used) | Harder to recycle |
| Cost | Cost-efficient | More expensive |
| Use at PouchDirect | ✔️ Standard in our pouches | ❌ Not used (less recyclable) |
Which level of protection do you need?
Not every product needs maximum protection. Use these simple guidelines:
• Short shelf-life dry goods? Go with standard PET or METPET.
• Aromatic or sensitive ingredients? Consider METPET or aluminium.
• Long shelf life and high product value? Aluminium is the safest choice.
Not sure what’s best? Get in touch with our packaging specialists. We’re happy to help!