Aluminum Foils Market Intelligence

Industry Outlook & Drivers

Global Market Outlook on Aluminum Foils

• The global production of aluminum foils was at 5.5 MMT during 2019, and it is expected to grow moderately at 5–5.5 percent (CAGR) until 2024 and reach 7 MMT

• Increase in demand from the automobile industry and rising consumption of flexible packaging (especially pouches) have bolstered the growth for aluminum foils

• Developed regions especially the US, Canada and Germany are primary consumers of aluminum foil owing to expanding demand from automobile and flexible packaging industry
• China stands atop the developing regions giving stiff competition for global converters. Impending trade restrictions might change this scenario in the near future

Supply Chain - Aluminum Foils

• Production optimization over the years have led to commercially available foil-rolling plants that can produce widths of up to 2150 mm and as thin as 0.006 mm at rolling speeds of 2500 meters/minute
• A natural technique to save energy would be collection and cleaning of CO2 from the electrolysis process for reuse

Global Aluminium Foil Market Size - Aluminum Foils

• Preference for convenient and lightweight packaging has driven vendors coming up with innovative aluminum foil packaging solutions catering to the organized retail and packaged foods market
• Aluminium foil with paper shows promise for growth in the packaging of dairy products in upcoming years
• The food and beverage industry is the largest end-user of aluminium foil, occupying nearly 30 percent of the total market share during 2018
• Demand from transportation industry in developed countries like the US and Germany followed by growing consumer spending on flexible packaging products from developing countries like China, Brazil, and India foster the growth for aluminum foils
• Growing applications of aluminium pouches increase product shelf life and hygiene as it does not alter chemical properties, lose shape or melt during exposure to sunlight

Global Aluminum Foil Demand by Type

• Rapid industrialization coupled with heavy air conditioner usage in India, Egypt, Iran, and UAE boost the need for industrial aluminum foils

• Blister foil is the major application in pharmaceutical industry, medical industry boom in emerging economies foster demand for aluminum foils

• Rolled Aluminum Foil: Aluminum foil is primarily consumed by packaging, transportation, and construction sectors

• The packaging industry took the largest share, ~41 percent, during 2019, followed by transportation 

• It is projected that global rolled foil consumption might increase by 5 percent CAGR from 2019 to 2024 with the transportation industry being the largest market

• The packaging industry took the largest share, approx. 41 percent, during 2018, followed by transportation

• It is projected that global rolled foil consumption might increase by 5 percent CAGR from 2018–2023 with the transportation industry being the largest market

• Backed Aluminum Foil: These include laminated, embossed, backed with paper, plastics and adhesives. Foil tapes constitute a major part in backed aluminum foils These are driven by their growing use in electrical and construction purposes giving superior adhesion and extended life

• Developed regions are expected to show moderate growth for backed aluminum foil used in industrial purposes, especially from the electricity sector that uses such foils for insulation purposes

• Emerging regions show promise with growing infrastructure in China and India

Industry Drivers

Lightweight 

• Aluminum foils can be extruded to 0.006 mm without losing its mechanical properties

• This feature primarily benefits the automobile industry 

Recyclability & Energy Efficiency 

• Compared to paper and plastics, aluminum is easy to recycle and the most recycled form are containers (beverage) 

• Recycling aluminum requires less than 92 percent less energy to make than new aluminum 

Durability 

• Although specialty films are being manufactured for pharma and food products, its acceptance compared to aluminum foil is limited 

• Aluminum foils exhibit superior barrier properties, resistance to heat and oxygen, insulation, moisture barrier properties, and aroma retention

Industry Constraints

Technology 

• A lack of technological intervention still allows the use of the Hall–Héroult process to smelt aluminum 

• This is a highly energy-intensive process, although, recent past has seen energy forms, such as fossil fuel and hydro/nuclear power 

Carbon Emission 

• 24.45 tons of CO2 emissions are generated per ton of aluminum foil produced 

• Aluminum foils use about 3.8 grams of per square foot whereas cling wrap uses only 1.7 grams 

Innovations in Aluminum Foil Packaging

PVC Alternative Line

• Tekniflex PXA, high-barrier Aclar® (PCTFE) laminated line. EVOH can also be laminated to the structure for additional oxygen barrier. 

• Tekni-Films also produces high and ultra-high thermoformable barrier materials, including the Flexapharm SBC series and PVC/Aclar laminates. 

• These structures provide an alternative to cold form foil enabling pharmaceutical companies to use a smaller blister card to contain the same number of tablets or capsules—or increase the count on a same-sized card. 

• The end result is material cost savings all the way through the packaging process, including cartons and cases, as well as improved production efficiencies.

PET based cold-form blister

• In the conventional cold form laminate, there are three layers –nylon, aluminum and PVC. 

• Uflex has developed revolutionary Alu-Alu packaging where special polyester film has replaced the conventional nylon and PVC while retaining aluminum making it an indigenous product since both PVC and BON have to be imported from other countries. 

• For this unique development, Uflex has also been granted a United States Patent recently. Alu-Alu packaging provides sustainability and cost optimization giving it an edge over conventional Alu-Alu packaging

Fast Tear Strip Foil

• Uflex has developed 20micron pin-hole free soft tempered foil. It contributes to providing a higher yield gain of 36% leading to cost savings for pharma companies. 

• Conventionally, pharma companies have been using 30 and 40 micron soft tempered Strip Foil pack laminate. 

• Fast Tear Strip Foil maintains the bursting pressure of the pocket with reduced foil thickness. 

• This foil conforms to all regulatory requirements of pharmaceutical products and also meets toxicology requirements. 

• Fast Tear Strip Foil proves to be a game-changer for the pharma industry globally and sees a potential aluminum foil market growth of 5000 tonnes annually in the aluminum foil market in India.

CRSF Foil

• The child-resistant & senior Friendly (CRSF) foils, developed by Uflex, are available in two types push-through and peel-push. 

• As the name suggests, it requires some amount of pressure for a child to open it. However an adult or senior can open it easily. 

• This protects unintentional damage to the foil which is common with conventional blister foils which get easily tampered during handling affecting the formulation