Aluminum Foil A1235 8079 for Flexible Packaging

12/29 2025

Aluminum foil alloys A1235 and 8079 sit at the heart of modern flexible packaging. They protect flavor, extend shelf life, and allow brands to ship sensitive products across continents without quality loss. Yet on the surface, they look almost identical: thin, bright metallic films on a roll. The real difference lies in the subtle metallurgy, temper, and production standards behind them.

Why A1235 and 8079 Dominate Flexible Packaging

Flexible packaging asks aluminum foil to do several things at once:

• Block oxygen, light, moisture, and aroma
• Laminate reliably with films and paper
• Survive forming, folding, and sealing without pinholes
• Run smoothly on high-speed packaging lines

Among commercial pure aluminum alloys, A1235 and 8079 are two of the most widely used grades for this job. They are both high-purity, non-heat-treatable alloys, but they are optimized differently:

• A1235 is the “classic” high-purity foil alloy, often chosen for standard barrier structures and cost-sensitive applications.
• 8079 is engineered for higher strength and better elongation at ultra-thin gauges, making it ideal where formability and pinhole resistance are critical.

From the outside, a yogurt lid and a pharmaceutical blister lidding may look similar. Inside the foil structure, though, the choice between A1235 and 8079 can make the difference between a smooth run at 400 packs per minute and a line full of micro-tears.

Chemical Composition: Subtle Differences, Big Practical Impact

Both alloys are based on aluminum with small additions that fine-tune properties. These additions influence grain structure, strength, and how the foil behaves when thinned to only a few microns.

A typical chemical composition range is:

A1235 Aluminum Foil – Typical Chemical Composition (wt%)

8079 Aluminum Foil – Typical Chemical Composition (wt%)

The distinction is the higher Fe content in 8079. This refines the microstructure and leads to:

• Better tensile strength, especially at thin gauges
• Improved elongation and tear resistance
• Enhanced performance in deep-drawing and complex forming

For converters running high-speed lines or producing very thin foil (down to 6–7 µm), 8079 often offers a wider processing window and fewer defects.

Alloy Tempering: How O, H14, H18 Change Real-World Performance

In flexible packaging, alloy is only half the story. Temper—how the foil has been annealed or work-hardened—directly affects formability, stiffness, and sealing performance.

Common tempers for A1235 and 8079 foils include:

• O (Annealed, soft): Fully annealed, maximum ductility, ideal for deep forming, complex folds, and tight bends. This is the workhorse temper for many laminates and household/food packaging foils.
• H14 (Half-hard): Moderately work-hardened, offering a balance of strength and formability. Often used where the foil must retain shape or stiffness yet still be workable.
• H18 (Hard): Maximum strength and stiffness with reduced elongation. Suitable for specialty applications where dimensional stability and resistance to mechanical damage are prioritized.

From a packaging engineer’s perspective:

• A1235-O is often used for standard laminated pouches, cigarette inner liners, and chocolate wraps.
• 8079-O is preferred for extremely thin lidding foil, pharmaceutical packaging, and applications where deep drawing without pinhole formation is critical.
• Harder tempers like H18 may appear in specific industrial or strip-pack blister applications where forming is minimal but mechanical strength is essential.

Parameters that Matter in Packaging Lines

When choosing A1235 or 8079 foil for flexible packaging, a few technical parameters govern performance and processability.

Thickness Range

• Typical ranges: approximately 6 µm to 40 µm
• 6–9 µm: ultra-thin foils for high-barrier laminates and inner layers
• 10–18 µm: common for general food laminations, sachets, lids
• 20–40 µm: used for heavier-duty lidding, tray covers, and some industrial wraps

8079 often shows an advantage in the ultra-thin range due to its better elongation and strength at low gauge.

Mechanical Properties (Typical)

These will vary by mill and temper, but indicative values in O temper:

• A1235-O:

  • Tensile strength: roughly 60–90 MPa
  • Elongation: about 10–20%

• 8079-O:

  • Tensile strength: roughly 80–120 MPa
  • Elongation: about 12–25%

The combination of higher strength and good elongation explains why 8079 is the go-to for demanding applications like pharmaceutical blister lidding.

Surface Quality

Good surface condition is critical for:

• Uniform coating and printing
• Consistent adhesive or extrusion lamination
• Low pinhole density

High-quality A1235 and 8079 foils are typically supplied with:

• Clean, oil-controlled surface
• Minimal roll marks, black spots, or inclusions
• Tight pinhole specifications based on thickness and application

Implementation Standards and Compliance

Aluminum foil for flexible packaging must do more than perform mechanically; it must also meet food safety and regulatory requirements.

Typical reference standards and requirements include:

• EN 546 (Europe): For aluminum and aluminum alloy foils
• ASTM B479 (USA): Standard specification for annealed aluminum and aluminum-alloy foil
• ISO 9001: Quality management systems certification at the mill
• Food-contact regulations linked to region, such as:
  • EU Regulation (EC) No 1935/2004 and related directives for food contact materials
  • FDA regulations in the United States for indirect food additives (where applicable)

For pharmaceutical applications, additional expectations include:

• Consistent mechanical properties for blister forming
• Tight control of residual lubricants and surface cleanliness
• Traceability and documentation throughout production

Manufacturers of A1235 and 8079 flexible packaging foil often also comply with:

• ISO 14001 for environmental management
• GMP-like practices for cleanliness in foil production and handling

Comparing A1235 and 8079 in Real Packaging Scenarios

From a purely metallurgical standpoint, 8079 looks like the “stronger” choice—but packaging decisions usually weigh multiple factors:

• For standard food laminates where gauge is moderate and forming is not severe, A1235-O delivers excellent barrier at a competitive cost, and its high aluminum purity appeals to brands emphasizing “clean” materials.
• For ultra-thin foil, deep-drawn lids, strip packs, and foil that must survive aggressive forming and fast processing, 8079-O or 8079-H temper typically offers higher reliability, fewer tears, and lower pinhole risk.
• In composite structures—such as PET/Al/PE or Paper/Al/PE—either alloy can be used, but 8079 is often selected when the foil layer is pushed to minimum thickness for cost or sustainability reasons.

In practice, many converters will qualify both alloys and optimize choice by product line: A1235 for mainstream flows, 8079 for premium or technically demanding packaging.

A Practical Way to Specify Foil for Your Project

When defining requirements with a supplier, a clear specification ensures the right balance of performance and efficiency. A typical request might include:

• Alloy: A1235 or 8079
• Temper: O, H14, or H18 depending on forming needs
• Thickness and tolerance: e.g., 9 µm ± 5%
• Width and coil ID/OD: matching your machinery
• Surface: one side bright / one side matte, or both bright, and defined oil level
• Application: food, dairy, confectionery, beverage, pharmaceutical, cosmetic, or industrial
• Applicable standards and regulatory requirements for your target markets

With these details in hand, a technically capable foil producer can fine-tune rolling practice, annealing cycle, and surface treatment to best suit your packaging line.

1235    8079   

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