Alu Alu Foil VS Plain Foil

Cold-formed aluminum foil and ordinary aluminum foil are both packaging foil materials with a relatively thick foil thickness obtained after calendering of aluminum alloy. They have many similarities in physical properties, but also have many differences.

The main difference between cold-formed medicinal foil and ordinary aluminum foil lies in their composition, manufacturing process and application.

Cold aluminum foil and plain foil have different compositions

Cold-formed medicinal foil:

Alu alu foil is a multi-layer structure that usually consists of three main materials: aluminum foil, polymer film (PVC or PVDC), and usually a layer of nylon (OPA). The layers are laminated together to achieve excellent barrier properties. Aluminum acts as the main barrier layer, while PVC provides strength and flexibility, and nylon increases puncture resistance.

alu-alu-foil

Ordinary aluminum foil
It is composed of 100% aluminum, sometimes coated with a thin layer of polymer or lubricant depending on its intended use. Plain foil has no additional lamination and a simpler structure.

plain aluminum foil

Alu alu foil vs plain foil manufacturing process

Cold formed pharmaceutical foil
Produced using a cold forming process where a multi-layer laminate is stamped or pressed into the desired shape (blister) without heating. Specialized equipment and precise lamination are required to ensure uniform barrier protection and formability.
Plain aluminum foil:
Manufactured through a process where aluminum sheets are rolled into thin sheets. It does not involve lamination or cold forming. The production process is simpler compared to cold formed pharmaceutical foil.

Different barrier properties

Cold formed pharmaceutical foil: Due to its multi-layer structure, it provides 100% barrier to moisture, oxygen and light, making it suitable for highly sensitive drugs (e.g. tablets or capsules that degrade in moisture or light). Provides excellent durability and protection to meet long shelf life requirements.
Plain aluminum foil: It provides a good but not absolute barrier to moisture, light and gases. Pinholes may form during the manufacturing process, reducing its effectiveness as a complete barrier.

Different applications

Cold formed pharmaceutical foil: Used in blister packaging in the pharmaceutical industry to package sensitive drugs. Preferred for packaging high-value and highly reactive drugs as it ensures maximum protection.
Ordinary aluminum foil: Widely used in household applications (e.g., food packaging, baking, and cooking). Also used for industrial and commercial purposes such as insulation, but it is not designed for sensitive pharmaceuticals.

Thickness and strength

Cold-formed pharmaceutical foil: Thicker due to its multi-layer structure (typical aluminum thickness is about 20-25 µm, plus polymer and nylon layers). This makes it stronger and more durable than ordinary foil.
Ordinary aluminum foil:
Usually thinner, ranging from 6 µm to 20 µm, depending on grade and use. It is more flexible, but has poorer puncture and tear resistance.

Difference in cost

Cold-formed pharmaceutical foil: More expensive due to its complex structure, advanced manufacturing process, and specialized applications.
Ordinary aluminum foil: Relatively cheap and widely available due to its simpler composition and production process.

Cold-formed pharmaceutical foil is designed for sensitive pharmaceutical packaging with high barrier requirements and long-term stability, while regular aluminum foil is a versatile, low-cost material suitable for general-purpose applications where barrier properties are less important.