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Aluminium foil
Also known as: aluminium foil, aluminum foil, AL foil, alu foil, foil laminate, foil pouch
Aluminium foil is a thin metal layer used in laminated pouches, providing the highest barrier to light, oxygen, moisture and aroma in flexible packaging.
Aluminium foil is pure aluminium rolled down to a few microns. In flexible packaging it is laminated between plastic films and delivers the highest barrier available against light, oxygen, moisture and aroma loss.
Where it is used
Foil is chosen when shelf life is critical: coffee with a degassing valve, milk and protein powders, pharmaceuticals, wet wipes, sachets and sterilised retort pouches. Typical gauges are roughly 7–12 microns in structures such as PET/AL/PE, PET/AL/OPA/CPP or kraft/AL/PE.
Trade-offs
- Sharp folds can cause pinholes, so an OPA layer is often added for flex resistance.
- Foil packs cannot have a window and cannot be microwaved.
- Foil laminates are generally not mechanically recyclable.
- Foil is heavier and costlier than metallised film.
Let your shelf-life target decide. For a few months, metallised film is often enough; for long storage or very sensitive products, foil is the safer choice. If recyclability matters, ask about EVOH or transparent barrier-coated mono-material options and compare test results.
Frequently asked
Are foil pouches recyclable?
Generally not through standard mechanical recycling, because the foil is bonded to plastic layers that cannot easily be separated.
How thick is the foil in a pouch?
Usually around 7–12 microns, depending on the barrier and flex resistance required.
Related terms
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