Laminated Aluminum Foil | Durable Packaging & Insulation Material

High-Performance Laminated Foil for Packaging and Insulation

Laminated aluminum foil is a multi-layer material designed to offer strong barrier protection, high durability, and excellent heat resistance. It is widely used in food packaging, cable insulation, HVAC ducts, pharmaceuticals, and industrial sealing.

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Laminated Aluminium Foil

Laminated aluminum foil combines a thin aluminium layer with other materials such as PET, PE, PVC, or paper. These layers are bonded together by adhesives or extrusion coating. The purpose is to improve strength, moisture resistance, heat sealing, and printability.

Main Benefits

• Strong barrier against moisture, oxygen, and light
• Durable and resistant to tearing
• Easy to shape and seal
• Excellent for long-life packaging
• Stable under high temperatures
• Lightweight and economical

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Materials Used in Laminated Aluminium Foil

Common Lamination Structures

Structure	Description
Alu + PET	High strength, good printing surface
Alu + PE	Heat-seal layer for food packaging
Alu + Paper	Eco-friendly and printable surface
Alu + PVC	Moisture barrier for pharmaceutical use
Alu + Woven Fabric	Strong insulation and waterproofing

Layer Functions

• Aluminum Layer: barrier against gases and moisture
• Plastic Layer: sealing ability and flexibility
• Paper Layer: surface printing and stiffness

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Types

Laminated aluminium foil comes in different types for different uses. Choosing the correct type depends on the application.

By Application

• Food-grade laminated foil
• Cable-grade laminated foil
• Pharmaceutical laminated foil
• Construction laminated foil
• HVAC laminated foil

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Technical Specifications

A clear list of specifications helps customers select the right laminated aluminium foil. Below is a small table with common values.

Standard Specifications

Item	Range / Value
Thickness	0.02–0.20 mm
Width	50–1600 mm
Alloy options	8011, 1235, 3003
Temper	O, H18
Core ID	76 mm / 152 mm
Lamination type	PET/Alu, PE/Alu, Paper/Alu

Physical Properties

• High tensile strength
• Heat resistance up to 120–150°C
• Excellent water vapor barrier
• Low permeability

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Applications

Laminated aluminium foil is versatile and widely used.

Industrial and Electrical Uses

• Cable shielding
• Transformer insulation
• HVAC duct insulation

Construction

• Roof insulation
• Vapor barrier layers
• Waterproofing membranes

Pharmaceutical Packaging

• Blister foil backings
• Medicine pouches
• Tablet and capsule wrapping

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Production Process

Steps in Laminated Aluminium Foil Manufacturing

• Aluminum foil rolling
• Surface cleaning and treatment
• Lamination by adhesive coating
• Extrusion coating for multi-layer structures
• Rewinding and slitting
• Quality control and testing

Key Quality Checks

• Thickness accuracy
• Bond strength
• Pinhole inspection
• Surface smoothness
• Sealing performance

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Packaging and Shipping

Laminated aluminium foil is packed carefully to avoid damage and contamination.

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Laminated Foil in One Sentence

Laminated aluminum foil is foil bonded to another layer, such as plastic film, paper, fabric, or fiberglass. The foil gives barrier. The other layer gives strength, print surface, or heat sealing.

Layer Added	What It Adds
Plastic film (PET, PE, PP, OPA)	Strength, print, heat seal
Paper or board	Stiffness, print, natural look
Woven or nonwoven fabric	Tear resistance
Fiberglass cloth	Heat and fire resistance
Scrim and kraft paper	Strong insulation facing
Bubble film	Thermal insulation

→ Foil blocks air, light, and moisture
→ The backing layer fixes the weak points of thin foil
→ Many structures are possible for different jobs

How to Read a Laminate Structure

Suppliers write laminate structures as a string. Each part is a layer, read from outside to inside.

Code	Meaning
PET	Polyester film, strong and printable
AL	Aluminum foil
PE	Polyethylene, heat sealable
PP	Polypropylene, heat resistant
CPP	Cast polypropylene, heat seal layer
OPA / BOPA	Oriented nylon, puncture resistant
Paper	Printable, stiff
PVC	Used in pharma blisters

Example Structures

Structure	Reading	Typical Use
PET12 / AL7 / PE50	12 µm PET, 7 µm foil, 50 µm PE	Sachets, pouches
PET12 / AL9 / CPP30	Print film, foil, heat seal layer	Cooking and retort pouches
Paper / AL / PE	Paper outside, foil barrier, PE inside	Sugar and powder packs
OPA15 / AL / PVC	Nylon, foil, PVC	Cold form pharma blister
AL / Kraft paper	Foil on kraft	Insulation facing

The numbers are the thickness in microns. A micron (µm) is 0.001 mm.

The Foil Layer: Alloy, Temper, and Thickness

The foil inside the laminate is thin. Alloy and temper still matter.

Alloy	Temper	Features	Typical Use
8011	O	Good balance, widely used	Pouches, wraps
8079	O	Very good ductility, fewer pinholes in thin gauge	Pharma and flexible packs
1235	O	High purity, very soft	Light laminates
1145	O	Very pure	Barrier laminates
3003	O / H	Higher strength	Thicker laminated sheets

Foil Thickness in Laminates

Foil Thickness	Barrier Level	Typical Use
6.0–6.5 µm	Good, some pinholes	Snack laminates
7 µm	Good	Sachets, tea, coffee
9 µm	Very good	Retort, stand-up pouches
12 µm	Very high	Heavy barrier packs
20–25 µm	Almost complete	Lidding, blister, long shelf life
30 µm and above	Maximum	Special uses

Lamination Methods Compared

How the layers are joined changes cost, strength, and food safety.

Method	How It Works	Pros	Cons
Dry lamination	Adhesive coated, dried, then layers pressed together	Flexible, many structures, strong bond	Needs curing time, solvent handling
Solventless lamination	Adhesive without solvent	Low emissions, clean	Needs controlled process
Water based lamination	Water carries the adhesive	Low odor	Less used for foil
Extrusion lamination	Molten plastic joins foil to another layer	No separate adhesive, strong seal layer	Needs extruder
Heat or thermal lamination	Heat bonds a coated foil to film	Simple	Limited structures
Wet lamination	Adhesive joins foil to porous paper	Good for paper	Slower drying

Quick Match

• Printed pouch with many layers: dry or solventless lamination.
• Foil with a thick PE seal layer: extrusion lamination.
• Foil to paper for wraps: wet or dry lamination.

Adhesives: What Holds the Layers Together

Adhesive Type	Strength	Typical Use
Polyurethane (PU), solvent based	High	General packaging
PU, solventless	High, low odor	Food packaging
Acrylic	Good	Tapes and labels
Water based	Medium	Paper laminates
Retort grade PU	Very high, heat resistant	Cooking pouches

Curing Time

After lamination, adhesive needs time to reach full strength. Many structures age for one to three days at a warm temperature before slitting or use. Follow the adhesive maker’s guide.

Product Families Made From Laminated Foil

Flexible Packaging Laminates

Lidding Laminates

Pharma Blister Laminates

Insulation Laminates

Foil bonded to kraft paper, fabric, or scrim. Used on pipes, walls, and roofs to reflect heat.

Foil Tape Laminates

Foil with adhesive and release liner for HVAC and duct sealing.

Cable Laminates

Foil bonded to PET film for shielding in cables.

Heat Shield Laminates

Foil bonded to fiberglass cloth for engine and appliance heat shields.

Family	Typical Structure	Foil Thickness
Snack and sachet	PET / AL / PE	6.5–9 µm
Retort pouch	PET / AL / CPP	9–12 µm
Lidding	AL / lacquer or AL / film	20–40 µm
Pharma blister	OPA / AL / PVC	45–60 µm
Insulation facing	AL / Kraft or AL / scrim	7–25 µm
Foil tape	AL / adhesive / liner	20–50 µm
Cable shield	AL / PET	9–20 µm
Heat shield	AL / fiberglass	20–50 µm

Why Laminate Instead of Plain Foil?

Point	Plain Foil	Laminated Foil
Strength	Low in thin gauge	High
Pinhole protection	Depends on gauge	Better, layers cover gaps
Heat sealing	Needs lacquer	Built in with PE or CPP
Print quality	Limited	Excellent on film or paper
Puncture resistance	Low	Higher
Flex crack resistance	Weak	Better
Cost	Lower	Higher

Barrier and Shelf Life Table

Barrier depends on the whole structure, not only the foil.

Structure	Oxygen Barrier	Moisture Barrier	Light Barrier
PET / PE	Low	Medium	None
Metallized PET / PE	Medium	Good	Good
PET / AL7 / PE	Very high	Very high	Complete
PET / AL9 / CPP	Very high	Very high	Complete
Paper / AL / PE	High	High	Complete

Foil at 7 µm or more, in a well made laminate, gives near total barrier.

Seal Layer Options

The inside layer decides how the pack closes.

Seal Layer	Seal Temperature	Features
PE	Low to medium	Good seal, widely used
LLDPE	Low to medium	Strong seal, tough
CPP	Medium to high	Heat resistant, good for cooking
EVA	Low	Soft seal, good for peel
Ionomer	Medium	Strong seal, good grease resistance
Peelable layers	Varies	Easy open lids

Quality Tests for Laminated Foil

Test	What It Shows	Typical Note
Bond strength (peel test)	Layer adhesion	Measured in N/15 mm
Heat seal strength	Seal quality	Measured in N/15 mm
Pinhole check	Barrier integrity	Light box or scan
Thickness	Layer and total gauge	Micrometer or gauge
Residual solvent	Food safety and odor	Gas test
Coefficient of friction	Slip on machines	Sliding test
Burst and drop test	Pack strength	Filled pack test
Odor test	Smell and taste risk	Panel or lab test

Target values depend on structure and product. Agree on a spec sheet with your supplier.

Common Defects and Fixes

Defect	Likely Cause	Fix
Delamination	Poor adhesive coating or short curing	Check coating weight and aging time
Tunneling (long wrinkles)	Uneven tension or stretch	Adjust tension control
Bubbles	Trapped air or moisture	Improve drying and nip pressure
Curl	Layer stress difference	Balance structure and tension
Blocking (layers stick)	Warm storage or high pressure	Control storage and roll hardness
Poor seal	Wrong seal layer or heat settings	Match sealing settings to film
Odor	Residual solvent	Longer drying, check adhesive system
Foil cracks	Folding too tight	Pick thicker foil or better structure

Storage and Handling

Item	Guideline
Temperature	Cool, room temperature
Humidity	Dry area
Sun and heat	Keep away
Roll position	On core, not on edge
Stacking	Do not overload
Shelf life of rolls	Check supplier guidance

Laminated Foil vs Metallized Film

Point	Laminated Aluminum Foil	Metallized Film
Metal layer	Solid foil, 6–25 µm	Thin vapor coating
Barrier	Very high	Good
Light block	Complete	Partial
Flex cracking	Can crack	More flexible
Cost	Higher	Lower
Best use	Long shelf life, strong barrier	Snacks and short shelf life

Sustainability Notes

Laminates mix materials, which can make recycling harder. Some options help.

Option	Idea
Thinner foil	Less material per pack
Mono-material designs	Use one plastic type when possible
Recycled content layers	Use recycled film where allowed
Design for collection	Label and match local systems
Aluminum recycling	Aluminum itself can be recycled many times

Check local rules before making environmental claims.

Specification Sheet: What to Include

Field	Example
Structure	PET12 / AL7 / PE50
Total thickness	Sum of layers
Foil alloy and temper	8011 O
Width	______ mm
Core ID	76 mm or 152 mm
Roll diameter and weight	______
Print	Plain or printed, number of colors
Seal type	Lip, fin, or peelable
Food contact	Yes or no
Tests	Bond, seal, pinhole

FAQ: Laminated Aluminum Foil

What is laminated aluminium foil used for?

It is used for food packaging, cable shielding, insulation, and pharmaceutical protection.

Is laminated foil food-safe?

Yes, food-grade laminations (PET/PE + Alu) are certified for contact.

Can laminated foil resist high temperatures?

Yes, depending on the film layer, it can resist up to 120–150°C.

Does laminated aluminium foil block light?

Yes, the aluminum layer provides excellent light-blocking ability.

What thickness is available?

Inquiry Template for Laminated Aluminum Foil

Product: Laminated aluminum foil
Structure: ______ (for example, PET / AL / PE)
Foil alloy and temper: ______
Foil thickness: ______ µm
Total thickness: ______ µm
Width: ______ mm
Core inner diameter: ______ mm
Print: plain / printed
Use: pouch / lid / insulation / tape / other
Food contact: yes / no
Quantity: ______ tons or ______ square meters
Destination port: ______
Documents: Mill test certificate, laminate test data