Within metal foils, aluminum foils made from 1235 alloy have gained tremendous popularity in producing flexible food packaging in roll formats. With advances in foil rolling and coating technologies, 1235 aluminum can now be produced in large jumbo rolls of up to 3-4 meters width and several kilometers length. These jumbo rolls have opened new possibilities for converting aluminum foil into various flexible packaging structures through high-speed packaging lines. They have enabled higher production efficiency and economies of scale for food brands and manufacturers. This article explores the characteristics and properties of 1235 aluminum foil that make it suitable for flexible food packaging. It also discusses common flexible packaging formats employing 1235 jumbo rolls and their applications.
Characteristics of 1235 alloy aluminum foil
1235 alloy is the most widely used composition for aluminum foil products. It contains 97-99% aluminum along with manganese, magnesium, copper and other elements. Some key characteristics that make 1235 aluminum foil ideal for flexible food packaging include:
Lightweight and malleable nature: At 0.009-0.2mm thickness, 1235 foil provides excellent barrier with minimal added bulk or weight to packaging. Its malleable characteristic allows it to be easily formed into various shapes during packaging conversions.
High barrier attributes: 1235 aluminum foil acts as an effective barrier against moisture, oxygen, light, bacteria and flavors due to its low permeability characteristics. This helps extend the shelf-life of foods.
Recyclability: 1235 aluminum foil has high scrap/recycling values and can be recycled repeatedly without any loss in quality - making it a sustainable packaging material. Over 70% of aluminum produced is still in use via recycling.
Heat resistance: 1235 foil can withstand higher temperatures during food processing, sterilization and retorting. It offers protection against thermal leaching and degradation.
Non-toxic and inert nature: Aluminum and its oxides are non-toxic and chemically inert. This ensures 1235 foil is safe for direct food contact applications.
Smooth and glossy surface finishes: Advances in foil rolling and coating technologies enable production of 1235 foil with ultra-smooth and glossy surfaces. This improves printability, writeability and enhance packaging appeal.
Aesthetic and barriers on both sides: Aluminum foil provides consistent moisture, gas and light barriers on both outer and inner sides. This allows 1235 foil based packaging to maintain branding/marketing graphics as well as protect the product interior effectively.
Common flexible packaging formats using 1235 aluminum foil rolls
Food manufacturers are making increased use of different types of flexible packaging structures developed using 1235 aluminum foil large jumbo rolls:
Pouches
Stand-up pouches, flat bottom pouches, spouted pouches are commonly produced on high-speed pouch makers and sachet machines using 1235 foil laminates. They are popular for snacks, coffee, teas, sauces and more. The foil interior helps extend shelf life while clear windows enable product visibility.
Lidding films
Aluminum lidding stock coated on one side with heat seal layer is often used for sealing trays, cups and tubs in applications such as yogurt, dairy, ready meals etc. The foil surface provides optimum barrier while the sealant layer ensures hermetic seals.
Laminates
Various co-extruded, adhesive laminated or extrusion coated structures consisting of layers such as LDPE, PP, acrylonitrile, nylon and aluminum foil are widely used in packaging frozen foods, meat, snacks and consumables. These laminates exploit the high barrier attributes of foil.
Bags/sacks
Standing/hanging bags made of aluminum vapor deposited or coated films laminated to kraft paper or polymers are used for coffee, pet foods etc. Metallized and foil layers improve barrier and functionality of paper bags while imparting shine.
Wraps
Heat shrinkable or stretch hood packaging commonly employ 12mm wide aluminum foil lidding seals or full wraps for packaging cheese, sausages or other deli products. They provide oxygen and moisture barrier as well as tamper evidence.
Sachets/stick packs
Heat sealed sachets made of aluminum foil laminated to films are ideal for single-serve condiments, sauces, sugar and stabilizer packets. The foil interior protects against dissolution while the clear film enables branding and consumption.
Common food applications
Given its excellent barrier attributes, 1235 aluminum foil finds widespread use in packaging various food categories:Snacks - potato chips, nuts, biscuits, crisps - Pouched/bagged snacks employ 1233 foil for maximum freshness. Foil luids are ideal for sealing multipacks.
Bakery - bread, buns, pastries - Aluminum foil wrappings are effective at blocking staling by retarding moisture loss and protecting against microbial spoilage.
Dairy - cheese slices, cream cheese - Aluminum lidding films seal tubs while foil substrates provide ideal barriers for pouches.
Confectionery - chocolates, candies, gums - Metallized foil substrates or inner foils protect hygroscopic sweets from moisture and ensure longer shelf-life.
Ready meals - curries, pastas - Foil lidding films seal trays for microwave use whereas laminates allow for freezing/thawing cycles.
Coffee/tea - roasted beans, ground coffee, tea bags - Standing bags with foil inner coatings block external odors and maximise freshness during storage.
Sauces/dry mixes - ketchup, mustards, seasoning powders - Aluminum foil sachets and stick packs offer ideal solution for single-serve condiments and mixes.
Trends and future of 1235 aluminum foil rolls in flexible packaging
With growing consumer demand for fresh, convenient and sustainable packaged foods, usage of 1235 aluminum foil in flexible food packaging formats is expected witness several new trends:
Larger jumbo coil widths and thinner gauges: Advances will enable unwinding of 1235 aluminum rolls of 4-5m width and thicknesses below 7.5 microns to access new packaging applications and formats.
Increased barrier and functionality: Developments in lamination, coating and metallizing technologies will further boost barrier performance of 1235 foil while integrating additional functionality like oxygen scavenging.
-Sustainable packaging designs: Emphasis on minimizing packaging materials and optimizing designs will drive more emphasis on downgauging foil wherever possible as well as transitions to aluminum foil paper laminates.
-Active and intelligent features: Emerging active/intelligent packaging systems will integrate 1235 aluminum foil substrates incorporated with antimicrobials, oxygen absorbers, moisture regulators etc.
-Aseptic formats: Highest barrier lamination structures employing ultra-thin 1235 foil will facilitate shelf-stable and extended shelf-life aseptic packaging of foods across categories.
-Digital printing compatibility: Advancements to achieve ultra-smooth surface finishes of 1235 aluminum foil will accelerate adoption of digital printing technologies for higher customization and branding opportunities.
-Blockchain integration: Blockchain based track and trace solutions can authenticate 1235 metalized foil and film packaging right from producers to consumers to tackle issues like counterfeiting and supply chain transparency.
With excellent barrier properties, sustainability, recyclability and increasing ability to deliver added functionalities - aluminum foil, particularly 1235 aluminum foil rolls have become staples in the flexible food packaging arena. Massive scale production of 1235 jumbo rolls have unlocked new efficiencies for food brands whilst retaining freshness, quality and safety credentials of packaged foods. Emerging digital and intelligent system integrations are projected to further catalyze adoption of 1235 foil based flexible food packaging solutions globally. Overall, the use of 1235 aluminum foil large rolls is anticipated to grow considerably to meet the packaging demands of food companies worldwide.
