Conventionally, aluminum foil laminated paper is made using approx. 20 g/m2 foil. Increasingly, vacuum metallizing vaporizes the aluminum to put a thin layer of only 100-300 mg/m2 (1-3 oz/3M) directly onto the paper.
Its handling characteristics during conversion are also better. Prior to vacuum metallizing, the base paper is first embossed, if required (eg: holographic papers), and then coated (eg: gravure coater) with lacquer to give a smooth surface able to support the high sheen finish.