Innovia launches metallised BOPP film for foil replacement

Innovia Films has introduced Propafilm CHBM, an 18µm metallised biaxially oriented polypropylene film developed to replace aluminium foil in selected flexible packaging laminates. Announced on 14 October 2026, the product is designed to provide high resistance to oxygen and moisture transmission while supporting packaging structures based predominantly on polypropylene.

Innovia identifies metal adhesion, thermal stability, optical density and a reverse-side treatment suitable for lamination or surface printing among the film’s technical characteristics. The intended applications include high-barrier food packaging, flat and stand-up pouches, and other formats in which converters are considering alternatives to conventional aluminium foil laminates.

Aluminium foil is widely used in flexible food packaging because a continuous foil layer provides a strong barrier against gases, moisture and light. These properties help protect products whose quality can deteriorate through oxidation, moisture absorption or the loss of volatile flavour compounds. However, a laminate combining foil with several polymer layers can be more difficult to recycle than a structure designed around one principal polymer family.

Propafilm CHBM uses a biaxially oriented polypropylene substrate with a deposited metal layer. Biaxial orientation stretches the polymer film in two directions during manufacture, influencing its dimensional stability, mechanical behaviour and suitability for converting operations. Metallisation adds a thin barrier layer that restricts the movement of oxygen and water vapour through the substrate.

This construction differs from incorporating a separate sheet of aluminium foil. The deposited metal layer is substantially thinner than conventional foil and remains part of the coated polymer film. Its barrier properties depend on the coating’s continuity and condition, making the quality of metallisation and the film’s behaviour during subsequent processing important to the finished packaging specification.

Innovia describes CHBM as an ultra-high barrier product, but the launch announcement does not provide numerical oxygen transmission rate or water vapour transmission rate results. Nor does it disclose independent comparative testing against specified aluminium foil laminates. The company’s description establishes the intended performance category without demonstrating that the film can replace every foil construction under all packaging conditions.

The suitability of a barrier structure depends on the food being packed. Products containing oxidation-sensitive fats may require particularly effective oxygen protection, while dry ingredients and snacks can be vulnerable to moisture uptake. Aroma retention, product composition, intended shelf life and storage conditions also influence the required packaging performance.

Packaging designers therefore need to establish the barrier requirements of each application before selecting a replacement film. An acceptable specification for one dry food may not provide adequate protection for another, even where the products use similar pouch formats. The same applies when storage temperature, distribution conditions or intended shelf life differ.

Metal adhesion is relevant because flexible packaging films undergo mechanical handling during printing, lamination, slitting, forming and sealing. Poor adhesion or damage to a metallised layer can affect barrier performance, particularly where the material is creased or subjected to repeated bending. Innovia identifies enhanced metal adhesion as a property of CHBM, although its announcement does not provide comparative flexing or finished-pack test results.

The reverse-side treatment is intended to support lamination and printing, allowing converters to incorporate the material into existing types of multilayer packaging structure. Thermal stability can also influence web handling and dimensional consistency during processing. These properties must be considered alongside the adhesives, sealant layers and other components used to manufacture a finished pouch.

The film’s 18µm gauge describes the supplied substrate rather than the thickness of the completed laminate. A finished pack will normally contain additional functional layers selected to provide sealing, mechanical strength, product compatibility and other required properties. Replacing foil therefore requires qualification of the full construction, rather than a direct comparison of the new film’s thickness with the foil being removed.

Innovia is positioning CHBM as a component for polypropylene-based packaging structures designed to improve recyclability. Using compatible polymer layers can reduce some of the material complexity associated with conventional combinations of foil and several plastics. Nevertheless, the inclusion of a metallised BOPP layer does not automatically make every completed laminate recyclable.

Adhesives, inks, coatings, sealants and other components influence how packaging behaves during sorting and recycling. Local collection arrangements and the technical capabilities of recycling facilities also determine whether a particular format can be recovered and reprocessed. The European Union’s Packaging and Packaging Waste Regulation increases the importance of assessing complete packaging designs against relevant recyclability requirements rather than relying exclusively on the properties of individual layers.

Food manufacturers must also examine how alternative materials behave on existing packaging machinery. Forming characteristics, seal integrity, web tension and resistance to damage can affect line performance. Changes that preserve laboratory barrier measurements may nevertheless require adjustments to sealing conditions or handling systems before the material can be used reliably in production.

Trials may include seal-strength measurements, leak testing, checks for damage following flexing and assessments of product condition during storage. Finished-pack testing is particularly important because defects introduced during converting or filling can compromise the protection provided by a high-performance film. A successful material substitution must preserve the required food protection and processing characteristics throughout distribution.

Alasdair McEwen, Business Unit Director Packaging EMEA at Innovia Films, said the company developed CHBM to provide the barrier performance associated with foil within a polypropylene-based structure. Innovia has not identified named customers, completed production conversions or measured shelf-life improvements arising from the launch.

Propafilm CHBM adds another material option for converters evaluating foil replacement in flexible food packaging. Its commercial adoption will depend on qualification in specific laminate constructions, confirmation of performance under production conditions and evidence that completed packs meet their intended recycling and product-protection requirements.