Is There Metal in Flexible Packaging? The Surprising Answer

When people think of metal, they picture something heavy, hard, and solid, not something you’d expect in light, soft, flexible packaging. So, is there metal in flexible packaging? The answer is yes, and it is very widely used.

It is very counterintuitive how metal could be present in a product as light and soft as flexible packaging. And secondly, why would metal be used in flexible packaging? Zhongjia Printing is a leading flexible packaging manufacturer specializing in water-based ink printing. Our company is committed to environmentally sustainable production, providing customized packaging solutions across food, pharmaceuticals, and daily-use products. Next, we will answer these two questions for you.

A Glimpse into History: Aluminum and Industrial Progress

A long time ago, when Napoleon III was at a banquet, holding an aluminum cup in his hand and looking proudly at the ministers underneath, I wonder if he foresaw that the cost of aluminum products would be cheaper than steel.

Aluminum, a metal with low density, good ductility, and high ductility, has been widely used in our daily life. After the human invention of pure aluminum extraction technology, and through the industrial revolution to reduce its cost dramatically, it has become an industrial product in the steamed bun.

Where Does Metal Exist in Flexible Packaging?

Aluminum Foil Layer

In high-barrier flexible packaging, a pure aluminum foil layer (approx. 0.007mm thick) is laminated between a printed surface layer and a heat-sealable bottom layer. This aluminum layer brings multiple benefits:

• Excellent oxygen and moisture barrier
• Lightproof properties
• High rigidity and premium feel

Applications: coffee pouches, powdered products, liquids, pharmaceuticals.

According to the Flexible Packaging Association (FPA), aluminum foil provides near-zero oxygen and moisture transmission rates, making it one of the most effective materials for long-term product preservation.

Metallized PET (VMPET)

For lighter and more economical packaging solutions, VMPET (Vacuum Metallized PET) is used. In this process, a micro-thin layer of aluminum is deposited onto a PET film in a vacuum chamber. It maintains a metallic look and barrier performance, but with much less cost and rigidity.

Applications: snacks, cookies, condiments, bread, dried goods.

Note: VMPET has lower barrier performance compared to pure aluminum. Ultra-high-barrier versions of VMPET are available but are costly and typically reserved for specialty applications such as pharmaceuticals.

Why Use Metal Materials in Flexible Packaging?

Flexible packaging is a multi-layer engineered material, not a single film. Based on customer needs and product features, we customize packaging structures with layers that perform various functions: sealing, printing, preservation, etc.

The key reason for using metal materials?

• To keep products dry, fresh, and protected by creating high-barrier packaging.

Aluminum and VMPET both help in:

• Preventing oxygen and moisture intrusion
• Blocking UV and light exposure
• Extending shelf life for sensitive products

Technical and Environmental Assurance

At Zhongjia Printing, we ensure product safety and sustainability through:

• Water-based inks (low VOC emissions)
• Solvent-free lamination
• Food-grade material sourcing

Rigorous quality inspections in our fully equipped laboratory

We partner with state-owned material suppliers to source certified raw materials and use advanced machinery to prevent metal oxidation and barrier degradation during production.

Conclusion: Metal + Flexibility = Innovation

The idea of metal in something as soft as flexible packaging might seem contradictory, but in reality, it represents technological advancement and environmental balance.

في تشونغ جيا للطباعة, we don’t just a water-based inks packaging manufacturer — we innovate with purpose. By combining eco-friendly practices and high-performance materials, we provide the best of both worlds: protection and sustainability. We export to more than 40 countries worldwide and hold certifications such as ISO22000, FDA, SGS, and BV, ensuring both product safety and sustainability.

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