Gousto’s new packaging: The recyclable solution powered by vacuum metallising

Gousto, a leading meal kit company, found itself at this crossroads, striving to deliver fresh, high-quality meals while minimising its environmental footprint. The company’s existing packaging, while effective, was not fully recyclable, creating a hurdle in meeting customer expectations for greener choices.

This is where vacuum metallised bags come in. They are an innovative recyclable alternative that maintains the protective qualities brands like Gousto need, without compromising on sustainability. But why the switch to these distinctive silver bags? What exactly is vacuum metallising and how does it fit into the meal kit market’s packaging needs?

In this blog, we will explore Gousto’s packaging challenge, the science behind vacuum metallising and how this innovative solution is helping the brand, and potentially many others, move towards a circular, more sustainable future.

The challenge: Creating sustainable, high-performance packaging for Gousto

Gousto’s meal kits need packaging that keep ingredients fresh and protected during shipping. Until now, this meant using multi-layered materials that weren’t easy to recycle.

But Gousto’s customers want packaging that is better for the environment. So, Gousto needed a solution that offers strong protection and can be recycled.

That is where vacuum metallised bags come in. These bags have a very thin metal layer applied in a vacuum, giving the packaging a silver look. This metal layer protects the food from light and moisture but still allows the bags to be recycled.

If you have wondered, ‘Why does Gousto use silver bags?’, it is because of this special vacuum metallising process. It is an innovative way to keep food fresh while being environmentally friendly.

Our development journey: From foil laminates to vacuum metallised bags

Our journey with Gousto began with a clear brief, to develop a liner that could protect their food products at temperatures above 30°C, be recyclable and affordable enough to keep meal costs reasonable.
We initially tested a foil laminated bag, which performed well in protecting the meals but could not be recycled due to the thickness of laminated aluminium foil.

To solve this, we developed a bag using vacuum metallisation technology. This approach allowed us to create a recyclable bag that maintained higher performance. After several design iterations and trials, we arrived at the solution Gousto uses today.

What is vacuum metallising? The science behind the solution

Vacuum metallising is a process where a very thin layer of metal, typically aluminium, is applied to a plastic film inside a vacuum chamber. The metal is heated until it evaporates, followed by the metal vapour being condensed onto the cooler surface of the substrate. This forms a uniform, adherent metallic film.

The vacuum environment is crucial in this process as it allows the metal to evaporate at a lower temperature and ensures that the vapour can travel unimpeded to the substrate. This results in a clean, controlled deposition.

Why thickness matters: Ultra-thin layers and LDPE recyclability

The metal layer applied in vacuum metallising is incredibly thin, typically in the range of 100 to 300 angstroms. This is thousands of times thinner than a human hair.

This ultra-thin coating is enough to protect food from moisture and oxygen without adding unnecessary bulk or heaviness.

Why such thin layers matter:

When applied to LDPE (low-density polyethylene), the thinness of the metal layer is critical for several reasons:

1. Preservation of material identity: The coating is so thin that it doesn’t change the basic properties of LDPE. The base remains the main material, keeping it recyclable.
2. Minimal interference in recycling: During recycling, LDPE is shredded, melted and reprocessed. The ultra-thin aluminium later breaks down or oxidises, having little to no effect on the quality of the recycled material.
3. No need for separation: Unlike thicker metal laminates or multi-layer composites, vacuum metallised LDPE does not require complicated separation before recycling. It works smoothly with existing recycling systems.
4. Environmental compliance: This thin aluminium layer meets regulations for safe, sustainable materials in food packaging, balancing performance with easy recycling and reuse.

In the meal kit market, this is especially important. Fresh ingredients need to be kept safe from external elements.

Vacuum metallised bags create a strong barrier that helps extend shelf life without using thick, non-recyclable materials.

It is a revolutionary step towards sustainable packaging that doesn’t compromise on performance.

How vacuum metallised LDPE supports a circular economy

A circular economy focuses on reusing materials and reducing waste. Vacuum metallised LDPE fits perfectly with this because the ultra-thin layer does not affect the recyclability. This means it can be recycled easily with existing LDPE streams without extra processing.

For Gousto, this packaging helps meet sustainability goals by cutting waste and supporting recycling. Many other brands face similar challenges and are looking for solutions like this to balance protection and eco-friendliness.

By using vacuum metallised LDPE, companies can comply with environmental standards, satisfy customers and move closer to a circular economy.

Beyond meal kits: Applications for vacuum metallised packaging

Vacuum metallised packaging is not just great for meal kits, it offers benefits for many other industries.

• Food packaging: It keeps food, coffee and other perishable items fresh by blocking moisture and light.
• Personal care products: It protects items like cosmetics and skincare from contamination and extends shelf life.
• Pharmaceuticals: It provides a reliable barrier against moisture and oxygen, ensuring medicines remain safe and effective.

This versatile technology delivers strong protection and recyclability, making it an ideal choice for brands aiming for sustainable packaging beyond just food delivery.

Let’s make sustainable packaging the industry standard

As LDPE is set to become widely recyclable by 2026, now is the perfect time for brands to embrace vacuum metallised packaging. At Swiftpak, we offer solutions that provide a smart way to combine high performance with recyclability. This helps businesses meet their sustainability goals without compromising on quality.

Discover how Swiftpak’s sustainable packaging solutions, including vacuum metallised packaging, can protect your products and the planet.

If you would like to find out more about how we can support your businesses’ packaging needs, get in touch with our expert team at Swiftpak today.