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How is Aluminum Foil Used for Packaging?

How is Aluminum Foil Used for Packaging?

Dec 6,2022
aluminum foil
We all know aluminum foil is a proven solution for packaging technology, logistics, branding flexibility, and more–but what is it about this material that makes it stand the test of time?

In this article, we explore how aluminum foil is used for packaging in the fast-paced modern business environment. We also describe how it differs from other materials and discuss some of the limitations imposed by its use.

With these product details, you'll gain a better understanding of what makes aluminum foil so versatile and enduring - and how it can benefit your brand in a range of different applications.

How is Foil Used for Packaging?

When most of us hear "aluminum foil," we think of those trusty little rolls of Reynolds that keep in our kitchen cabinets and drawers. As an alternative to plastic wrap and parchment, nonstick aluminum foil is always on hand to help prepare and wrap food with ease.

Heavy-duty aluminum foil is also used in food storage to help prevent freezer burn. Additionally, it is used in high-temperature grills and ovens in many American homes due to its dull nonstick coating.

But in the world of product packaging, aluminum foil is a real game changer. Everything from individually wrapped snacks to bulk shipments of sensitive materials and chemicals can be protected with aluminum foil.

The material completely blocks moisture, light, and oxygen – all factors that can make or break a product’s stability and quality during shipping and storage. These unwanted elements can come together in a perfect storm of oxidation and bacterial growth, causing the fat to spoil and the product to be ruined en route to its destination.

Fortunately, foil packaging allows manufacturers to lock in the flavor and other key characteristics of their products. This helps keep the supply chain in top shape and ensures customer satisfaction. Therefore, foil products are widely used in food and pharmaceutical packaging.

Why Do We No Longer Use Tin Foil?

Although aluminum foil is sometimes called the tin foil, the two materials have very different compositions and functions. Tin foil, the predecessor to aluminum foil invented in the early 20th century, is rarely used anymore, although the name is just a convenient shorthand.

Let's find out why we no longer rely on tin foil for packaging and household chores, and why aluminum foil remains the most widely used and trusted material of its kind.

Tin Foil and Aluminum Foil

Introduced during the industrial boom of the late 1800s, tin foil was more crude and limited in function than the best-selling aluminum foil we know today.

While tinfoil is a welcome change from other packaging and preservation methods, it also has significant drawbacks, including a lack of malleability and the noticeable taste it leaves on food.

Thankfully, only a few decades later, innovators found a viable alternative to aluminum foil, fulfilling the original purpose of tin foil and improving the overall product. Aluminum is more flexible, more cost-effective, and doesn't impart any flavor to the product. Standard aluminum foil is also used more widely in everything from industrial applications to common household needs like baking pan liners.

Today, aluminum foil offers the highest standards of protection and reliability, making it the best in its class.

Benefits of Aluminum Foil

Without delving into aluminum's unique chemical properties, it's worth exploring the benefits of this foil in the modern packaging industry.

Below, we describe the main characteristics of aluminum foil and indicate which applications are most relevant to certain industries at various stages of the supply chain.


Sourcing and procurement are critical parts of the packaging, shipping, fulfillment, and other components of the business cycle. When businesses do not have a reliable source of packaging materials—whether for food, pharmaceuticals, or other sensitive products—delays pile up and resources are wasted.

The good news is that the wide availability of cheap aluminum allows companies of all sizes to meet their shipping and packaging needs on short notice and on a reasonable budget.


Aluminum foil has few competitors when it comes to bringing perishable goods to market in a safe and efficient manner. Comparable only to polyvinyl compounds such as mylar, aluminum exhibits excellent longevity in terms of its structure and effectiveness. It preserves products much longer than other solutions, and for food and pharmaceuticals, it widens the window of opportunity for sale and consumption.

Consider the impact of materials such as aluminum foil from the perspective of business owners who want products to last longer on store shelves and provide customers with a wider window of time to enjoy them at home.

Environmental Sustainability

It's not just a buzzword. Environmental awareness is a top consideration for consumers and producers, which means addressing every aspect of the supply chain to improve sustainability.

Again, aluminum foil shines here, offering a low-impact production footprint and being reusable and fully recyclable. This foil can indeed be used multiple times if used carefully in the kitchen.

The same principle applies to foil security seal bags and other packaging solutions, encouraging customers to think twice.

Using aluminum foil is arguably better for the environment in the long run than plastic materials that rely heavily on oil, gas and water.


We've come a long way since the basic use case of aluminum foil, so it's time to think beyond candy wrappers and bakeware. Modern foils can be highly customized for various packaging functions, offering manufacturers and marketers unprecedented versatility.

Aluminum now allows for innovative, functional packaging in the food, supplement, pharmaceutical, nutraceutical, cannabis dispensary and other industries. Packaging technology now also includes child-resistant features, helping to ensure that families are protected at home.

High Barrier Protection

When aluminum foil is of the proper thickness and equipped with the correct barrier mechanism, it has few competitors. This helps companies create safe food-grade packaging that seals tightly and minimizes damage and waste. This extra level of protection can provide peace of mind, peace of mind, and other intangibles that are integral to a satisfied customer base.


Shipping costs have skyrocketed along with every other aspect of the supply chain, so any way to ease the burden is good for companies everywhere. Aluminum foil offers just that, reducing the weight of your cargo using a space-saving lightweight material.

Business owners know the impact of saving just a few ounces per shipment when crunching the numbers. With aluminum, this return is certain.

Things You Shouldn't Do With Aluminum Foil

Despite the many advantages of aluminum foil rolls, there are a few things you should never do with aluminum foil rolls in your home or food service establishment.

Aluminum foil should never be used in the microwave (although it is approved for most ovens). To be on the safe side, be sure to read the manufacturer's instructions on the device before use.

While aluminum foil is oven safe, do not place it in direct contact with food while baking in the cooker, or you may end up with unevenly baked food. Skip using foil as an oven liner and instead use a sheet of foil and place the shiny side up on the grill under a dripping pie or another item.

Finally, despite popular belief, wrapping baked potatoes in foil does not reduce the baking time.

From cans and bags to large packaging needs, aluminum foil is the clear winner–even after a hundred years in the spotlight. If you want to buy aluminum foil, please contact us.

PENGYUAN is a professional custom aluminum foil coating manufacturer. We have 3 vacuum coating machines and 8 PE extrusion coating production lines, guided by 6S management system. As the largest extrusion coating base in China, the company has obtained ISO9001, ISO14001, ISO45001 production standards for the whole system.
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Learn more from our FAQ
Which to choose Aluminum foil coated PE or Metalized pet film coated PE ?

It depends on what product to be made in final procedure. Aluminum foil coated pe is with at least 97% reflectivity, it can be bonded to EPE foam but also most of time for laminated with bubble. Metalized pet film coated PE with lower reflectivity ,but it is with strong surface.

I am a insulated liner/bag manufacturer,what product do you suggest?

There maybe bubble lamination machines and heating pressure lamination machines in your factory, we suggest Aluminum foil 7mic+PE20mic, and Metalized PET film12mic+PE15mic.

If i would like to get a quote ,what information shall i need to know first?

You are request to telling application, material structure,thickness and roll width and quantity.

What is the MOQ and how is packaging?

MOQ is 1000kgs for each product, packaging depends on roll size, common width is 1200mm and 1500mm, length are 4000m to 5000m per roll. Rolls can be vertically packed on pallet also accept to do horizontal suspending packaging.

Is this product by wet lamination or by dry lamination?

Both wet lamination line(extrusion coating) and dry lamination line(glue coating) are equiped in our Pengyuan group.

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ZHEJIANG PENGYUAN is the leader of extrusion coating, the professional manufacturer & supplier of PolarFoil