Packaging materials are a dime a dozen – carton or synthetic material, plastic or cardboard, glass or wood or metal. And this is where opinions often differ; what is a particularly sustainable packaging material, which material is recyclable, what is suitable for which product, what is the best packaging material?

Many materials are controversial. And yet they are necessary, as they all have the same goal after all: to provide the best possible protection. Depending on what needs to be protected, the material must meet certain requirements. For example, it should be particularly stable and unbreakable, should not be particularly heavy or should provide a good barrier against air or moisture.

One material that can easily meet the diverse requirements of packaging materials and yet is more likely to be considered the hidden champion in packaging solutions is aluminium! Aluminium is indeed omnipresent – but perhaps so much so that we often don't even notice it. It is a component of many bicycles and even cars, you find it in kitchen utensils or in the television, even many smartphones have a housing made of aluminium.

In packaging, it is currently often just one component of different solutions, for example as part of a laminate as in the tetrapack, or a component of the packaging as in yoghurt lids or the foil of a tablet blister. Yet aluminium is an extremely versatile material that offers a number of advantages - especially for packaging in industries such as food, beverages, pharmaceuticals and cosmetics, where it is often used as a component of various types of packaging. We have collected the five most elementary advantages of aluminium in packaging:

Aluminium is a very light material, with about one third the density of steel, it has a low weight. Despite its lightness, it is an extremely strong metal that has the same strength in relation to weight as modern steel and titanium. This makes it ideal for various packaging solutions. Finally, its light weight makes it easier to transport products and reduces the overall weight of the packaging, which additionally reduces transport costs.

Aluminium is naturally resistant to corrosion. It forms a thin oxide layer on the surface, which consists of aluminium oxide (Al2O3) and protects the underlying metal from moisture and oxygen. This keeps packaged products fresh and protected much longer. Actually, the natural oxide layer is formed by the reaction of aluminium with oxygen in the air. It is only a few nanometres thick and yet impermeable to water and other corrosive substances, for example. It is also almost indestructible: if it is scratched or damaged, a new layer forms immediately and restores the protection.

Aluminium offers an excellent barrier against light, moisture, odours and contaminants or other environmental influences – which is why it is perfect for any product packaging. This barrier effect protects the contents from almost all external influences, thus extending the shelf life and preserving the quality of food and beverages, for example, which is why aluminium is particularly popular for beverage cans: the barrier function preserves the taste and the contents have an extremely long shelf life. Aluminium cans are extremely light, easy to stack, almost unbreakable and thanks to their excellent temperature conductivity, drinks can be cooled in no time at all and stay cool for longer.

Aluminium is incredibly versatile: it can easily be shaped into different forms and therefore offers enormous flexibility in the design of packaging solutions. This can be thin-walled, for example, to save even more weight, or slightly thicker to be particularly strong and resistant to ensure optimal protection of sensitive products. Packaging with aluminium is therefore possible in various sizes, shapes and designs and can thus meet a wide range of requirements.

Aluminium cans are among the most popular food packaging solutions. Due to the complete barrier function of aluminium, it preserves the taste and offers a very long shelf life – the perfect packaging for any beverage. The cans are very light, very stackable and almost unbreakable. Thanks to the material's thermal conductivity, the drinks in the can can be cooled down in no time and stay fresh and cool for longer.

Like aluminium itself, the cans are also fully recyclable without the material losing any of its quality. Unlike other packaging materials for beverages, used aluminium cans are hardly degraded, mechanically stressed or chemically damaged in the recycling process.

Did you know? It only takes 60 days for a single aluminium can to be produced, filled, distributed, consumed and recycled into a new can.

Incidentally, this also makes the aluminium beverage can an ideal packaging solution for achieving the EU's recycling targets for 2025 and 2030! Bottlers and also many consumers are aware of the sustainability of beverage cans, after all, it consists of only one material and no printed design or label has to be removed.

For more than 100 years, aluminium foil has been one of the most important and versatile packaging materials, helping to protect, preserve and present food, confectionery, dairy products, pet food, ready meals, beverages and pharmaceuticals. And today, aluminium foil is as relevant as ever in the packaging sector, just as it should be an indispensable kitchen tool in almost every household.

Today's consumers are more environmentally conscious than in the past and want sustainable packaging that not only does the job but is also recyclable and reusable. Hardly any other flexible packaging material can rival aluminium foil in this respect: Every last bit of aluminium ever produced can be recovered and reused.

What's more, the modern consumer wants not only an effective and environmentally friendly packaging solution, but also a stylish one. Aluminium foil has a certain quality shine to it, whether it is the natural glossy appearance of the material or a beautifully printed or embossed decoration on the packaging. Alufoil's high flexibility also allows it to take the shape of a product - for example, the shape of an Easter bunny or Father Christmas. The adaptability enables particularly individual product packaging.

Did you know? The thinnest aluminium foil is only 0.006 millimetres, or 6 micrometres, thin. Less than a human hair!

And yet even the thinnest foil provides a complete barrier against light, moisture and odours. Normally, aluminium is rolled to a thickness of less than 0.2 millimetres. It extends the shelf life of food, care products or medicines and can now be found in every conceivable market: from sterile beverage cartons, pouches, bags, lids, wrappers, blister and strip packaging as well as various foil containers – a stylish all-rounder, in fact!

You want to learn more? Here you will find sources, references and further information:

European Aluminium Foil Association (EAFA) Key Messages

European Aluminium