Aluminum Foil

Aluminium foil is produced by rolling sheet ingots cast from molten billet aluminium, then re-rolling on sheet and foil rolling mills to the desired thickness, or by continuously casting and cold rolling. To maintain a constant thickness in aluminium foil production, beta radiation is passed through the foil to a sensor on the other side. If the intensity becomes too high, then the rollers adjust, increasing the thickness. If the intensities become too low and the foil has become too thick, the rollers apply more pressure, causing the foil to be made thinner.

The continuous casting method is much less energy intensive and has become the preferred process.For thicknesses below 0.025 mm (1 mil), two layers are usually put together for the final pass and afterwards separated which produces foil with one bright side and one matte side. The two sides in contact with each other are matte and the exterior sides become bright; this is done to reduce tearing, increase production rates, control thickness, and get around the need for a smaller diameter roller.

Some lubrication is needed during the rolling stages; otherwise, the foil surface can become marked with a herringbone pattern. These lubricants are sprayed on the foil surface before passing through the mill rolls. Kerosene based lubricants are commonly used, although oils approved for food contact must be used for foil intended for food packaging.

Aluminium becomes work hardened during the cold rolling process and is annealed for most purposes. The rolls of foil are heated until the degree of softness is reached, which may be up to 340 °C (644 °F) for 12 hours. During this heating, the lubricating oils are burned off, leaving a dry surface. Lubricant oils may not be completely burnt off for hard temper rolls, which can make subsequent coating or printing more difficult.

The rolls of aluminium foil are then slit on slitter rewinding machines into smaller rolls. Roll slitting and rewinding is an essential part of the finishing process.