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Pactrum Flexible Packaging
Materials & Finishes 4 min read September 2026

Metallised Pouches: Vacuum Aluminum Barrier & Light Protection

Understand metallised barrier films: vapor-deposited aluminum, zero light transmission, oxygen protection, and fat rancidity prevention for snacks and spices.

Quick Answer

A metallised pouch is constructed using a multi-layer polymer laminate that incorporates a vacuum-deposited microscopic aluminum layer (MET-PET or MET-BOPP). This layer blocks 100% of visible light and ultraviolet radiation and dramatically lowers oxygen and moisture vapor transmission rates, protecting oily snacks, nuts, and spices from oxidation and staleness.

Essential Key Points
  • Vacuum-deposited aluminum layer provides near-zero light transmission.
  • Prevents photo-oxidation of fats in roasted nuts, fried snacks, and namkeen.
  • Significantly lighter and more puncture-resistant than thick aluminum foil.
  • Pactrum offers metallised finishes across all 5 pouch families.

Comparison Overview

Barrier ParameterStandard Clear PET/PEMetallised PET/PEPure Aluminum Foil
Light / UV Transmission High (Transparent) Zero (< 0.1% transmission) Zero (Total block)
Oxygen Barrier (OTR) Moderate (40–60 cc/m²/day) High (< 1.5 cc/m²/day) Exceptional (< 0.1 cc/m²/day)
Moisture Barrier (WVTR) Moderate (3–5 g/m²/day) High (< 1.0 g/m²/day) Exceptional (< 0.1 g/m²/day)
Flex-Crack Resistance Excellent High (Durable flex) Moderate (Prone to pinholes)

The Chemistry of Light & Oxygen Protection

Foods containing natural vegetable oils, dairy fats, or sensitive aroma terpenes degrade rapidly when exposed to atmospheric oxygen and ambient supermarket lighting. Photochemical oxidation causes rancid off-flavors within weeks if barrier packaging is inadequate.

Vacuum Aluminum Vapor Deposition

In a vacuum chamber, pure aluminum is heated until it vaporizes and condenses onto a moving web of polymer film. The resulting metal layer is only 0.02 to 0.05 microns thick—providing high-performance barrier shielding without the rigidity or pinholing risk of solid metal foil.

CATALOGUE DISCOVERY

Recommended Stand-Up Pouches

Standardized specifications relevant to Metallised Pouches.

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Frequently Asked Questions

Are metallised pouches recyclable?

Because metallised films fuse aluminum to polymer substrates, recycling depends on local multi-layer laminate recovery infrastructure. Monomaterial high-barrier alternatives are emerging for specialized circularity requirements.

Can you see through a metallised pouch?

No. The vapor-deposited aluminum coating creates an opaque silver mirror surface. For product visibility, consider hybrid pouches with a clear front and metallised back.

Ready to review pouch dimensions and samples?

Explore our complete catalogue across all standardized flexible pouch families.