For decades, flexible packaging has played a critical role in protecting products, extending shelf life, and enhancing brand presentation. However, as sustainability continues to reshape the packaging landscape, manufacturers and brand owners alike are being challenged to balance performance with recyclability.
Traditionally, high-barrier packaging applications—such as those used for pet food, coffee, and powdered products—relied heavily on aluminium foil or metallised polyester (MPET) films. These materials offer excellent protection against oxygen, moisture, and light, all of which are vital for maintaining freshness and product integrity. Yet, despite their technical superiority, these conventional structures are multi-material laminates that are difficult or impossible to recycle in existing recycling streams.
Today, that’s changing.
Enter Recyclable High-Barrier Films
Recent advancements in material science have led to the development of recyclable high-barrier films—a new generation of packaging materials designed to deliver comparable performance to traditional barriers while being compatible with mono-material recycling streams.
One of the most promising innovations in this space is Metallised Polyethylene (MPE). This film offers a sustainable alternative to MPET or aluminium, while maintaining the essential protective qualities required for long shelf life products.
From MPET to MPE – A Technological Shift
Conventional MPET films are polyester-based and typically combined with polyethylene (PE) sealant layers to form laminates. The challenge is that this combination of PET and PE makes the overall structure non-recyclable in standard PE recycling streams.
By contrast, MPE films are mono-material structures, metallised directly onto a PE substrate. This design allows them to be fully recyclable within existing polyethylene recycling systems, eliminating the need for material separation.
The critical performance parameters for these films are their:
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OTR (Oxygen Transmission Rate)
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WVTR (Water Vapour Transmission Rate)
As long as these barrier properties meet the product’s requirements, MPE-based films can effectively replace MPET or foil laminates in a wide range of applications.
Applications in Pet Food and Coffee Packaging
Pet Food Packaging
Pet food products—particularly dry kibble and treats—require strong protection against oxygen and moisture to prevent rancidity and preserve nutritional value. Historically, this has been achieved using aluminium foil or MPET-based laminates.
By transitioning to metallised PE high-barrier structures, brands can now achieve similar shelf life performance while aligning with growing demands for recyclable flexible packaging. The result is a pouch that not only maintains product freshness but also supports circular economy goals.
Coffee Packaging
Coffee is another category where barrier performance is non-negotiable. Exposure to oxygen rapidly degrades flavour and aroma, while moisture can ruin the grind consistency. Traditionally, coffee bags rely on aluminium foil layers to ensure long shelf life.
With today’s advanced MPE films, roasters and coffee brands can achieve excellent oxygen and moisture barriers within a mono-material recyclable pouch, maintaining aroma protection and visual appeal—without compromising on sustainability credentials.
The Sustainable Edge for Brands
For brand owners, the move to recyclable high-barrier films represents more than a technical upgrade—it’s a strategic advantage. Consumers are increasingly aware of packaging waste and are rewarding brands that commit to recyclable and circular solutions.
By adopting metallised polyethylene films, companies can:
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Reduce their environmental footprint
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Meet retailer and regulatory sustainability targets
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Communicate a clear, positive sustainability message to consumers
All while maintaining the high shelf-life performance their products demand.
Looking Ahead
As the packaging industry continues to innovate, the shift toward recyclable mono-material solutions is accelerating. The emergence of MPE high-barrier films demonstrates that sustainability and performance no longer need to be at odds.
For packaging suppliers and brand owners alike, these materials mark the next generation of shelf-life protection—a future where flexible packaging can be both high-performing and truly recyclable.
At Law Print, we’re proud to be at the forefront of this transition—helping our customers move toward more sustainable, high-performance packaging solutions. Whether you’re packing pet food, coffee, or other long shelf life products, our team can help you identify the right recyclable barrier film to meet your technical and sustainability goals.
Looking to invest in sustainable packaging? We’ll support you every step of the way — from strategy to implementation. Along the journey, we’ll offer tailored recommendations to boost efficiency, lower costs, and unlock added value in your final product.
Contact us on +44 (0) 161 440 7302. Alternatively, follow this link to complete our contact form.
