After the first comparative study between multimaterial and recyclable films , Packstyle once again turned to the expertise of SCF International to further investigate the environmental impact of its materials—this time extending the analysis to films with an aluminum barrier.
The Life Cycle Assessment (LCA) approach enabled the company to scientifically assess the environmental performance of its materials throughout their entire life cycle.
The LCA analysis serves a dual strategic function. On one hand, it acts as an internal evaluation and decision-making tool, capable of precisely identifying the strengths and weaknesses of different materials and guiding production choices toward more efficient and sustainable solutions. On the other hand, it provides an external benchmark for transparency and credibility, as it is based on an internationally recognized scientific methodology that delivers objective, comparable, and consistently interpretable data.
Packstyle’s flexible pouches have an inherent competitive advantage: thanks to their lightness and compactness, they require less raw material and energy during production, significantly reducing emissions and resource consumption compared to rigid packaging solutions.
With this new study, Packstyle takes another step forward, broadening the scope of its analysis beyond packaging to explore the characteristics and performance of materials themselves. In doing so, the company strengthens its commitment to measurable, transparent sustainability, grounded in rigorous technical analysis and objectively verifiable results.
A Comparison Between Two Packaging Solutions
The goal of this second phase of analysis was to evaluate and compare the environmental performance of two types of flexible pouches produced by Packstyle: one made with metallized recyclable film and the other with an aluminum barrier film.
The study aimed to identify which of the two solutions has the lower overall environmental impact, taking into account the entire life cycle of the product.
A Comprehensive “Cradle-to-Grave” Analysis
A cradle-to-grave approach refers to an analytical method that takes into account every stage of a product’s life cycle, from the extraction and processing of raw materials to its final disposal.
In the context of the LCA study on Packstyle’s pouches, this means assessing the environmental impacts associated with each phase, including:
The two pouch types were compared based on the amount of material required to package one liter of product, which in this case corresponds to 6.67 medium-sized pouches (15×25+7 cm).
All available finishes—glossy, matte, and soft touch—were also considered to realistically represent the entire product range.
As with the previous study comparing multimaterial film and recyclable film, this analysis went beyond the mere evaluation of main environmental indicators, adopting a thorough and detailed approach.
Five key parameters were assessed to provide a complete picture of performance: climate change (CO₂ eq), photochemical ozone formation, acidification, water resource use, and stratospheric ozone depletion.
The Weight of Raw Materials
The cradle-to-grave approach made it possible to analyze in detail every stage involved in the production of a Packstyle pouch.
As already highlighted in the previous study, it clearly emerged that raw material production is the most environmentally impactful phase, responsible for the largest share of CO₂ emissions and natural resource consumption.
Data analysis, broken down by material type and finish, shows that production alone accounts for no less than 80% of the various environmental indicators considered.
The subsequent phases — processing, transport, and disposal — contribute much less overall, with a combined impact of less than 5%.
An exception is found in soft touch pouches, where transport from the material manufacturer to Packstyle’s facility shows a higher-than-average impact.
The Results: Less CO₂, Lower Impacts, More Recycling
When analyzing the impact of the different indicators by material type and finish, the comparison between the two pouch types is clear-cut.
The metallized recyclable film pouch shows significantly lower environmental impacts than the aluminum barrier film pouch across all analyzed categories.
The positive results achieved by the metallized recyclable film stem not only from the reduced use of aluminum and complex polymers, but also from the overall higher efficiency of the material throughout its life cycle.
This type of film requires less energy and raw material during production and can be mechanically recycled at the end of its life, thereby reducing the amount of waste sent to landfill or incineration.
The raw material production phase for metallized recyclable film packaging shows notably lower environmental impacts, particularly in categories related to water resource use and stratospheric ozone depletion.
Waste management and end-of-life performance also show significant improvements, with impacts reduced by 30% to 90% across different categories, thanks to the material’s recyclability and reduced landfill disposal.
These results confirm the effectiveness of metallized recyclable film as a more sustainable solution, capable of combining technical performance with a tangible reduction in environmental footprint.
A Concrete Step Toward the Circular Economy
Based on the data collected, the metallized recyclable film fully embraces the principles of the circular economy, promoting resource reuse and helping to significantly reduce the overall environmental impact of packaging — all without compromising its technical or functional performance.
The LCA analysis confirms the consistency of Packstyle’s environmental strategy: focusing on flexible, mono-material, and recyclable solutions makes it possible to tangibly reduce the environmental footprint of packaging while maintaining the performance standards demanded by the market.
Packstyle’s flexible pouches, inherently lightweight yet durable, already provide a competitive advantage — they require less raw material and energy during production compared to rigid alternatives, thereby contributing to a meaningful reduction in emissions and resource consumption.
The comparison between recyclable film and aluminum barrier film, together with the results of the previous study on multimaterial films, highlights a crucial point: choosing recyclable materials ensures a real environmental advantage in the later stages of the life cycle, particularly at end of life, where the possibility of recycling becomes a key factor in the overall sustainability of the packaging.
Looking Ahead
Packstyle’s journey toward sustainability is far from over. The company will continue to monitor and deepen its understanding of the environmental impact of its packaging solutions, working closely with qualified technical partners to improve production efficiency and actively contribute to European goals for emission reduction and the promotion of plastic recycling.
As this study also highlights, the Life Cycle Assessment (LCA) is a strategic tool of great value — for the company, as it allows scientific validation of its choices and guides innovation in a sustainable direction; and for the consumer, as it provides transparent, verifiable information that supports more conscious and responsible choices.
Each Packstyle pouch embodies a tangible commitment — a commitment to a lighter, more efficient, and environmentally respectful future.