what is the thickness of aluminum foil

Aluminum foil is one of the most common and versatile materials used in households, industries, laboratories, and commercial packaging around the world. From wrapping food to insulating spacecraft, aluminum foil plays a vital role across many applications. But have you ever wondered, what is the thickness of aluminum foil

Although it appears paper-thin to the eye, aluminum foil comes in a wide range of thicknesses depending on its use. In this article, we explore the standard thicknesses of aluminum foil, how it is measured, different types of foil grades, and why thickness matters in both everyday and high-performance applications.

What Is Aluminum Foil

Aluminum foil is a thin sheet of aluminum metal that is rolled or cast to achieve its final thickness. It is typically made from high-purity aluminum ingots and undergoes multiple stages of rolling under high pressure until it reaches the desired thinness.

Aluminum foil is widely used for:

• Food packaging and preservation

• Household cooking and baking

• Pharmaceutical blister packs

• Heat insulation and shielding

• Industrial lamination

• Battery and electronics applications

Its lightweight nature, excellent thermal conductivity, and barrier properties make it irreplaceable in many sectors.

Standard Thickness of Aluminum Foil

The typical thickness of aluminum foil varies depending on the intended use. In general, the foil thickness is measured in microns (µm) or millimeters (mm). One micron is one-thousandth of a millimeter.

Common classifications include:

• Standard household foil: 10 to 20 microns

• Heavy duty foil: 25 to 30 microns

• Extra thick foil: 40 microns and above

• Converter foil (used in laminates): 6 to 9 microns

• Pharmaceutical foil: 20 to 25 microns

• Battery foil: 10 to 20 microns, often in rolled coils

To put it into perspective, human hair is about 70 to 100 microns thick, so even heavy-duty aluminum foil is significantly thinner.

At sasaaluminum, we manufacture high-precision aluminum foil rolls starting from as thin as 6 microns up to 200 microns, depending on customer requirements and industry standards.

How Is Aluminum Foil Thickness Measured

There are several ways to measure the thickness of aluminum foil:

1. Micrometer

A micrometer is a precise mechanical tool that measures thickness to the nearest micron. It clamps gently around the foil and gives a direct reading.

2. Weight Method

You can measure foil thickness indirectly using this formula:

Thickness = (Weight ÷ Area) ÷ Density

Given:

• Weight in grams

• Area in square centimeters

• Density of aluminum = 2.7 g/cm³

This method is commonly used in labs or for quality control.

3. Optical Gauges

In industrial settings, non-contact gauges using lasers or X-rays provide real-time thickness readings during production.

Why Thickness Matters in Aluminum Foil

Even a few microns can make a big difference in how aluminum foil performs. Here’s how thickness affects functionality:

1. Barrier Protection

Thicker foil offers better protection against moisture, oxygen, light, and bacteria. That is why pharmaceutical packaging and long-term food storage use foil above 20 microns.

2. Mechanical Strength

Thin foil tears easily. For wrapping food, a minimum of 10 to 12 microns is needed. Heavy-duty foil at 30 microns resists punctures and holds shape better.

3. Heat Resistance

In cooking or grilling, thicker foil provides better insulation and resists burning or melting. It also helps retain heat for longer periods.

4. Flexibility and Conformability

Thin foil is more flexible and better for wrapping irregular shapes. Thicker foil is more rigid but durable.

The optimal thickness is always a trade-off between protection, cost, and handling convenience.

Types of Aluminum Foil by Thickness and Use

Household Foil

Typically 12 to 16 microns, used for food storage, baking, or lining cookware.

Catering and Foodservice Foil

Ranges from 18 to 25 microns for commercial kitchens where durability is essential.

Industrial Foil

Ranges from 30 to 100 microns for applications like HVAC insulation, cable wrapping, and lamination.

Pharmaceutical Foil

Usually around 20 to 25 microns, designed for blister packaging, tablet protection, and sterilization.

Battery Foil

Extremely precise foil from 10 to 20 microns used in lithium-ion battery anodes and cathodes, requiring tight tolerances and surface consistency.

At sasaaluminum, we supply all major foil types in rolls, sheets, or custom formats for food, medical, electronic, and clean energy sectors.

Global Standards for Foil Thickness

Foil production and thickness tolerances are governed by standards such as:

• ASTM B479 (Standard Specification for Aluminum Foil for Capacitors)

• EN 546 (European standards for aluminum and aluminum alloys foil)

• ISO 7271 (Aluminum and aluminum alloys – Foil – Measurement of thickness)

These standards define allowable thickness ranges, testing methods, and dimensional tolerances to ensure consistency across industries.

Can Aluminum Foil Be Too Thin

Yes. If the foil is too thin for the application, it can:

• Tear during packaging

• Fail to block light or oxygen

• Wrinkle or delaminate in laminates

• Melt during cooking

Thin foils under 9 microns are best used as part of multi-layered laminates in packaging where strength is provided by backing films.

In contrast, foils over 25 microns can stand alone and provide structural strength along with barrier properties.

Sustainable Aspects of Aluminum Foil Thickness

Choosing the right thickness is also a matter of sustainability:

• Thinner foil means less raw material and lower cost

• Proper thickness prevents food spoilage, reducing waste

• Recyclability depends on cleanliness and foil integrity

• Laminated foil may be harder to recycle if bonded with plastic

Recycling-friendly foil solutions, such as mono-material packaging, are now being developed by innovative manufacturers like sasaaluminum to meet environmental goals.

Tips for Choosing the Right Foil Thickness

• For home use, go with 15 microns or higher for baking and leftovers

• For restaurant kitchens, 25 to 30 microns is ideal for grilling and oven trays

• For industrial wrapping, aim for 30 microns or more to withstand transport and weather

• For medical and pharma, use high-barrier foil above 20 microns

• For electronics or energy storage, consult a technical supplier for precise specs

Final Thoughts

So, what is the thickness of aluminum foil The answer depends on how it is being used. Aluminum foil generally ranges from 6 microns to 200 microns, with each application demanding a specific balance of flexibility, strength, barrier performance, and thermal resistance.

Whether you are wrapping a sandwich or engineering a battery cell, understanding foil thickness is key to material performance and cost efficiency.

With advanced rolling, slitting, and testing facilities, sasaaluminum offers a full range of high-precision aluminum foil solutions. From thin converter foils to heavy-duty industrial wraps, our team ensures each roll meets global standards and customer expectations.