foillaminate

Foillaminate, or foil laminate, is a composite material formed by bonding a thin metal foil, typically aluminum, to a substrate such as paper or polymer film. The foil provides a barrier to moisture, gases, and light, while the substrate contributes mechanical strength and surface properties like printability or texture.

Common configurations include aluminum foil laminated to PET, BOPP, or paper, using an adhesive layer or extrusion, producing a flexible, heat-sealable film suitable for packaging. A related variant is metallized film, where a thin aluminum layer is deposited on a plastic film rather than a separate foil layer.

Manufacturing involves roll-to-roll lamination, where the foil and substrate are joined with an adhesive or extrusion layer, followed by drying and finishing steps such as printing and coating. The result is a multilayer film that can be processed on standard packaging equipment.

Applications are widespread in packaging, including food packaging for snacks and coffee, pharmaceutical blister packs, confectionery wrappers, and other consumer packaging. Foillaminates are also used in decorative laminates and certain insulation or shielding roles in electronics or building materials.

Advantages include strong barrier properties against moisture, oxygen, and aromas, good stiffness, and versatile surface finish for printing. Limitations center on recyclability and end-of-life handling due to the multilayer structure, potential delamination under flexing or heat, and the need to manage adhesive residues. Environmental considerations note that separation of layers is often required for recycling, and many foillaminate products are treated as part of mixed-material waste streams.

Regulatory aspects involve ensuring food-contact compatibility and adherence to packaging safety standards for products using foillaminate materials.