Aluminum foil, with its excellent barrier properties, flexibility, and environmental friendliness, has become the core material for cigarette inner liner packaging. The mainstream cigarette packaging products adopt 8011 aluminum alloy, which combines strength and ductility, superior to pure aluminum foil. Its surface has higher hardness, capable of withstanding the mechanical stress of high-speed packaging equipment, while maintaining good dead-fold properties (no rebound after folding) to ensure packaging tightness.
Aluminum foil for cigarette packaging can effectively block moisture, oxygen, and light, thus preserving the aroma and freshness of tobacco. The foil is usually laminated with paper, and this composite material can also be printed for branding purposes. Its barrier properties help maintain consistent product quality during storage and transportation.
Haomei aluminum foil size for cigarette packaging
- Material: 8011 Thickness: 5.5-30μm
- Temper: Soft (O) temper for flexibility
- Laminate: Typically bonded with paper (20-25 gsm) for added strength
- Coating: May include a heat-sealable lacquer for sealing purposes
- Surface: Often has a bright side and a matte side
Aluminum foil for cigarette packaging mainly uses 8011 aluminum alloy (Al-Fe-Si series), which is a type of 8-series alloy designed specifically for packaging applications. 8011 aluminum alloy contains added Al-Fe-Si elements, and with more than 1% total alloying content, it offers significant performance advantages.
Compared with other alloy systems, 8011 alloy demonstrates unique advantages in cigarette packaging applications. Compared to pure aluminum, 8011 aluminum foil provides higher strength and better ductility, along with excellent barrier properties that effectively prevent moisture, oxygen, and other gases from entering the package, thereby extending the product’s shelf life.
| Alloy Type | Main Characteristics | Application Scenario |
| 8011 Aluminum Alloy | Al-Fe-Si series, high strength, good ductility, strong barrier properties | Mainstream cigarette inner liner packaging, dominant in the market |
| 1235 Aluminum Alloy | Industrial pure aluminum, Al content >99.35%, good formability | Special packaging requiring high surface quality |
| 8079 Aluminum Alloy | 8-series aluminum alloy with excellent specific performance | Specific cigarette packaging applications |
Thickness of aluminum foil for cigarette packaging
Standard thickness range and classification
The standard thickness range of aluminum foil for cigarette packaging is 5.5–30μm (0.0055mm to 0.03mm).
Ultra-thin aluminum foil
- Thickness range: <5.5μm (0.0055mm)
- Technical level: some production capability down to 0.0045mm
- Application: special high-end packaging applications
Regular thickness aluminum foil
- Thickness range: 6–7μm (0.006mm–0.007mm)
- Technical level: industry standard thickness (double-zero foil)
- Application: mainstream specification for cigarette inner liner packaging
Thick specification aluminum foil
- Thickness range: 12–30μm (0.012mm–0.03mm)
- Technical level: high strength, high stiffness requirements
- Application: filter tip packaging, hard pack packaging
Application differences of various thickness specifications
| Thickness Specification | Main Characteristics | Application Scenario | Advantages |
| 0.006mm (Double-zero foil) | Soft temper (O), good elongation, high flexibility | Soft pack cigarette inner liner packaging | Moisture-proof and aroma retention, suitable for complex packaging processes |
| 0.012–0.015mm | Higher strength, good stiffness, tear resistance | Filter tip packaging, hard pack packaging | Withstands greater mechanical stress, maintains shape |
| 0.009–0.02mm | Medium strength, good flatness | Specially designed cigarette packaging | Balanced performance and cost, suitable for customized needs |
| <0.0055mm (Ultra-thin) | Extremely high flexibility, high precision control | High-end special cigarette packaging | Lightweight, low material cost, premium texture |
Different foil thicknesses have clear application divisions in cigarette packaging. This differentiation results from balancing performance requirements and cost efficiency.
Surface treatment and coating technology of aluminum foil for cigarette packaging
Antibacterial and anti-mold coating
The upper surface is coated with antibacterial agents (such as nano-silver ions), and 2–3% of anti-mold additives are incorporated into the adhesive to inhibit the growth of microorganisms such as Aspergillus niger.
Moisture-resistant coating
The bottom surface is coated with water-based polyurethane hot-melt adhesive to achieve moisture resistance and effectively extend the product’s shelf life.
Functions and advantages of aluminum foil for cigarette packaging
- Barrier property: Protects tobacco from external factors such as moisture, oxygen, and ultraviolet light, which can reduce tobacco quality and flavor.
- Aroma retention: The aluminum foil creates a sealed environment that helps preserve the unique aroma of each cigarette blend.
- Humidity control: The foil blocks water vapor, prevents mold growth, and maintains the desired tobacco humidity.
- Mechanical strength: When laminated with paper, the foil provides the strength and flexibility needed for high-speed production without tearing.
- Aesthetic appeal and branding: The metallic surface is ideal for printing, allowing customized brand designs, colors, and logos.
- Foldability: The foil can be folded into desired shapes and firmly fixed, tightly wrapping the cigarettes.
Material structure and types of aluminum foil for cigarette packaging
Cigarette aluminum foil paper is not pure aluminum foil but a composite material, typically structured as follows:
- Base layer: Paper (such as glassine paper, kraft paper, etc.), providing mechanical strength and toughness, making it easy to fold and package.
- Barrier layer: High-purity aluminum attached to the paper through vacuum metallization or rolling processes, forming an extremely thin aluminum layer that provides the core barrier function.
- Coating: The outer side of the aluminum layer usually has a protective lacquer (such as varnish) to prevent scratching or oxidation; the inner side (in contact with cigarettes) typically has a heat-seal adhesive, enabling sealing with the inner frame paper or other parts during packaging.
According to the aluminum layer processing method, there are two main types:
Rolled aluminum foil paper:
Aluminum ingots are repeatedly rolled to produce extremely thin aluminum foil (typically 6.5–7 microns), which is then laminated with base paper.
Advantages: Excellent barrier properties, strong metallic appearance, bright and glossy surface.
Disadvantages: Slightly higher cost, relatively lower recyclability.
Vacuum metallized paper:
In a vacuum environment, metal aluminum is heated and evaporated, allowing it to evenly deposit on the paper surface, forming a thinner aluminum film (about 0.03 microns).
Advantages: Lower aluminum consumption, lower cost, good barrier properties, and because the aluminum layer is extremely thin, it is easier to degrade naturally or recycle, making it more environmentally friendly. It has now become the mainstream in the market.
Why choose 8011 aluminum foil for cigarette packaging?
Mechanical performance advantages
The 8011 alloy offers high strength, good ductility, and excellent formability. Its superior elongation allows it to withstand complex processing operations on high-speed packaging lines without breaking.
Packaging performance requirements
8011 aluminum foil features excellent surface smoothness and flatness, making it easy to heat-laminate or coat with other materials. It effectively prevents moisture absorption in tobacco, maintaining cigarette flavor and quality.
Dead-fold characteristics
8011 aluminum foil has a unique no-rebound folding property, allowing it to maintain its folded shape without springing back. This ensures that the packaging remains stable after folding, preserving the aesthetic and structural integrity.
Corrosion resistance
Through the addition of magnesium elements and appropriate annealing treatment, 8011-O foil has good corrosion resistance, maintaining long-term integrity without forming pits or cracks that could harbor bacterial growth.
Chemical composition of aluminum foil for cigarette packaging
Common alloys include 1235, 8011, and 8079, selected for their high purity (aluminum content >99.5%) and controlled trace elements (e.g., Fe ≤0.15%, heavy metals <10 ppm) to meet food-grade safety standards. Magnesium (≤0.25%) and other alloying elements enhance printing and forming flexibility.
| Elements | Composition /% | ||
| 8011 | 1235 | 1145 | |
| Si | 0.50-0.90 | 0-0.65 | Si+Fe 0.55 |
| Fe | 0.60-1 | 0-0.65 | - |
| Cu | 0-0.10 | 0-0.05 | 0.05 |
| Mn | 0-0.20 | 0-0.05 | 0.05 |
| Mg | 0-0.05 | 0-0.05 | 0.05 |
| Cr | 0.05 | - | - |
| Zn | 0-0.10 | 0-0.1 | 0.05 |
| Ti | 0-0.08 | 0-0.06 | 0.03 |
| V | - | 0-0.05 | 0.05 |
| Al | Rem | Rem | Rem |
Mechanical properties of aluminum foil for cigarette packaging
| Alloy | Temper | Thickness /mm | Tensile strength /MPa | elongation after break /%, (not less than) | |
| A50mm | A100mm | ||||
| 1145 1235 | O | 0.0060 - 0.0090 | 45-95 | 0.5 | |
| 8011 | 50-105 | 1.0 | |||
Number of pinholes in aluminum foil for cigarette packaging
| Thickness/mm | Total number of pinholes/m2, not more than | Number of pinholes with a diameter greater than 0.2mm/m2, not more than | Number of pinholes with a diameter greater than 0.3mm/m2 |
| 0.0060 | 1500 | 150 | O |
| 0.0060-0.0065 | 1000 | 100 | |
| 0.0065-0.0070 | 500 | 50 | |
| 0.0070-0.0090 | 200 | 20 |
Cigarette Packaging Aluminum Foil Manufacturing Process
- Rolling and Thinning: The process starts with aluminum ingots, which are rolled under controlled conditions to achieve the required thickness and uniformity.
- Surface Treatment and Coating: After rolling, aluminum foil may undergo additional treatments, such as light polymer coatings or varnishes. These coatings enhance its sealing properties and protect it from environmental factors during storage and transportation.
- Lamination: In some packaging solutions, aluminum foil is laminated with other materials (such as paper or specialized polymers). This creates a multilayer structure that combines the barrier properties of aluminum with the printability and structural advantages of other materials.
Applications of Aluminum Foil in Cigarette Packaging
- Liner: Aluminum foil is commonly used as an inner lining for cigarette packaging. It comes into direct contact with the product, ensuring that cigarettes are protected from moisture and oxygen before the package is opened.
- Quality Preservation: By preventing the ingress of air and moisture, aluminum foil helps maintain the chemical stability of tobacco. This is crucial for preserving the intended flavor, aroma, and overall quality of cigarettes.
- Aesthetic and Branding: In addition to functional advantages, the reflective finish of aluminum foil enhances the overall visual appeal of the packaging. It provides a premium look and feel, often used as part of brand identity.
Specific Market Applications:
Soft Packaging: 6-micron thin foil (e.g., 1235 alloy) is favored in markets such as the UAE for its flexibility and tactile quality. "Paper-backed" foil variants improve stability in high-speed production processes.
Premium Brands: Metallized or embossed foils (e.g., gold, silver) enhance visual appeal and brand differentiation.
Aluminum foil remains indispensable in cigarette packaging, balancing technical performance with creative branding opportunities. Innovations in alloy formulations, sustainability, and automation compatibility continue to drive its application, particularly in growing markets such as the Middle East.