Putting LCA into Practice: Insights from METIVO® VB
In the first two articles of this mini-series, we explored why Life Cycle Assessment (LCA) is a powerful tool for sustainable packaging—and how its four structured phases help translate environmental data into real-world decisions.
But what does it actually look like in practice?
In this final article, we walk through a real-world LCA case study using METIVO® VB as a concrete example. Designed to deliver a premium look with a minimal footprint, METIVO® VB offers an excellent example of how LCA reveals the environmental impact of a packaging material—from raw materials to manufacturing—and how smart design choices can drive measurable sustainability gains.
A Packaging Innovation Designed for Sustainability
Metallic packaging typically relies on complex, multi-material structures that are difficult to recycle and resource-intensive to produce, resulting in a high environmental cost. METIVO® VB was developed to change that. It provides the high-gloss, high-barrier performance that brands expect from traditional foil laminates, but with a dramatically smaller environmental footprint.
At its core, METIVO® VB is a mono-material paper product—over 95% of its composition is high-quality paper. A microscopically thin aluminum layer, just 20 to 30 nanometers thick, is applied through a vacuum metallization process. This ultra-light coating accounts for less than 1% of the material’s weight. This means that METIVO® VB retains its paper identity and can be recycled in standard paper streams without the need for special separation or processing.
Despite using a fraction of the aluminum typically found in foil-laminated packaging, METIVO® VB delivers strong barrier properties against moisture, oxygen, and light, making it ideal for food, personal care, and other sensitive applications. It also offers the same eye-catching, mirror-like finish consumers associate with premium brands.
In short, METIVO® VB is designed to behave, print, and recycle like paper while performing like a high-end barrier laminate.
Why METIVO® VB Has a Smaller Footprint
The sustainability promise of METIVO® VB isn’t just about design; it’s backed by data. To quantify its environmental advantages, we have conducted a full life cycle assessment (LCA) following internationally recognized ISO 14040 and 14044 standards. The goal was to evaluate the material’s performance across key environmental impact categories and compare it to conventional packaging options, particularly those using thicker aluminum foils or film laminates.
Aluminum plays a critical role in the barrier properties of packaging but is also a key contributor to greenhouse gas emissions due to its energy-intensive production. According to the Ecoinvent 3.1 database, the global warming potential (GWP) of primary aluminum can exceed 16 kg CO₂e per kilogram.
In this context, metallized paper—such as the one assessed in this study—offers a considerably more sustainable alternative to laminated flexible packaging, primarily due to the significantly lower quantity of aluminum it employs.
The figure below compares the global warming potential (GWP 100a, IPCC 2013 method) associated with two different masses of aluminum, both based on the same background dataset. The orange column represents a higher quantity of aluminum, typical of what is used in foil-based laminated packaging, while the blue column represents a much smaller quantity, consistent with the levels applied through vacuum metallization.
As illustrated, increasing the aluminum mass from metallization levels to foil levels can lead to nearly 95 times higher CO₂ emissions—despite serving a similar purpose in terms of barrier performance or visual effect.
This example highlights how even seemingly small material optimizations can result in major climate benefits. By achieving the same packaging functionality with a fraction of the aluminum, metallized solutions offer a more resource-efficient and environmentally responsible alternative.
The study used a cradle-to-gate approach, covering all processes from raw material extraction to finished packaging leaving the factory. This boundary was selected to focus on the stages where NMS has the greatest influence: sourcing, processing, and production.
The functional unit, the basis for comparison, was defined as one square meter of finished packaging material, which provides the same protective and visual function as the packaged product. This consistent unit enabled a fair evaluation of how METIVO® VB compares to multilayer alternatives.
Due to its significantly reduced aluminum usage, optimized energy efficiency, and reliance on renewable fiber instead of fossil-based plastics, METIVO® VB was expected to have lower environmental impacts, a prediction confirmed by the LCA results.
What the LCA Reveals: Impact Reduction Across Key Areas
The Life Cycle Assessment confirmed that METIVO® VB delivers real sustainability benefits, particularly when compared to traditional plastic films or foil-laminated papers.
Its most notable strength lies in climate impact: thanks to an ultra-thin aluminum layer—less than 1% of its weight—METIVO® VB emits just 0.1 to 0.15 kg of CO₂ per square meter, far below that of conventional multi-material packaging.
The LCA confirms that METIVO® VB is built on principles of environmental responsibility, with results showing ranges due to the different recognized methodologies applied in the assessment.
Water use, for example, is just 0.003 to 0.005 cubic meters per square meter, a testament to our sustainable sourcing and water‑saving production processes. This careful approach helps protect one of our most vital resources for future generations.
Thanks to its renewable fiber base, METIVO® VB requires only 0.03 to 0.05 kg of oil equivalent per square meter. Energy‑efficient systems such as trigeneration and on‑site renewables further reduce the need for fossil resources, making production both cleaner and more resilient.
Even in packaging, the benefits are clear. Emissions linked to smog formation remain exceptionally low—0.0003 to 0.0005 kg of NOx‑equivalent per square meter—thanks to advanced solvent recovery systems that capture and recycle over 99% of VOCs, supporting cleaner air for all.
Together, these results demonstrate how smart design and responsible production make METIVO® VB a high-performance solution with a significantly lower environmental footprint.
Sustainability Beyond the Numbers:
While the LCA confirms that METIVO® VB has a low environmental impact, its performance is deeply rooted in its production process. Sustainability isn’t just built into the design; it’s embedded in the production process.
At NMS’ facility in Italy, production is powered by a high‑efficiency trigeneration system that meets the majority of the site’s energy needs. This system produces electricity, heat, and cooling from a single fuel source, significantly reducing emissions. The rest comes from the national grid (with a strong share of renewables) and on-site solar panels.
In addition, a closed-loop solvent recovery system captures and reuses over 99% of volatile organic compounds (VOCs) during coating and drying. This minimizes air pollution and helps maintain compliance with strict environmental standards.
Along with responsibly sourced paper and minimal aluminum use, these choices ensure that METIVO® VB is a genuinely lower-impact solution, from its raw materials to its production.
The case of METIVO® VB shows what’s possible when smart design meets scientific measurement. With a structure based on renewable materials, ultra-low aluminum content, and clean, efficient manufacturing, this metallized paper achieves high performance with a significantly reduced environmental footprint.
More importantly, the Life Cycle Assessment doesn’t just validate these benefits—it makes them visible, measurable, and actionable. From carbon savings to water conservation and cleaner air, the LCA results offer clear proof points that support sustainability claims and help customers make informed decisions.
In an industry under pressure to reduce impact without compromising quality, METIVO® VB is a compelling example of how LCA can guide the development of packaging that performs—for both the product and the planet.
Please note that the results presented are based on preliminary Life Cycle Assessment (LCA) data and have not yet undergone third-party verification. We are fully committed to sustainability and are excited to share the results of our metallized paper, with plans for verification through a third-party EPD as soon as possible. We look forward to demonstrating the verified impact of our efforts on environmental performance.
Ready to make sustainability measurable?
If you’re looking for packaging solutions that combine premium performance with proven environmental benefits, METIVO® VB shows what’s possible. Backed by real data and Life Cycle Assessment, it’s more than just a sustainable option—it’s a smarter choice for the future.
Get in touch to learn how METIVO® VB can support your sustainability goals and elevate your packaging strategy.