Alufoil’s History – The Breakthrough
(1945 - 1999)

Technical advances conquer new markets

After the Second World War alufoil began a spectacular period of growth with worldwide alufoil production quadrupling to 280,000 tonnes between 1950 and 1960. At the same time both rolling speeds and rolling widths increased dramatically, helping to meet the high demand for converted products.

A series of landmark technical developments signalled remarkable success in packaging markets. For instance in Europe the first alufoil food containers were used for bakery products appearing on the market in 1948, soon followed by a variety of other foodstuffs.

European and North American markets were increasingly catching on to alufoil benefits as an efficient packaging material but, although by this time the industry it is nearly five decades old, the technology of rolling, processing and conversion is still based mainly on practical experience not on solid scientific foundations.

The need for scientifically-based research is accepted and in co-operation with associated food technology institutes, intensive investigations began into the deformation of alufoil, the strength of heat-sealed seams and the vapour impermeability of packaging. Investigations also extended to composites and laminates made up of different materials including alufoil and paper, and/or plastic or cellulose film.

Thanks to these advances alufoil with its total barrier to light, moisture, and penetration of aroma and flavour, was now in use for perishable products throughout Europe. Alufoil's aesthetic attributes were not forgotten and its bright metallic or matt finish plus its compatibility with printing technologies were beginning to be used to good effect.

Markets in which alufoil was gaining increasing acceptance in the 1950s included thin neck foil for wines and beers where its decorative potential was used to marketing advantage; and lidded semi-rigid foil trays, lacquered where necessary to protect against acid, which could be filled on conventional filling and packaging equipment.

The early 1950s saw freezers becoming more affordable and as they began to appear in consumers' homes the TV Dinner, the forerunner of today's ready meal, was created in the US in 1954. Packed in compartmented aluminium trays the idea soon spread to Europe.

Developments such as these signposted the beginnings of a revolution in consumer convenience with alufoil used successfully for frozen foods, soup and stock cubes; and even heat-sealable pouches for coffee, cocoa, tea and spices.

But it was not only consumer packaging that benefited, by the 1950s semi-rigid alufoil was also in use for technical applications such as industrial products including fats, waxes and adhesive compounds. In the building and construction industry alufoil was being used as thermal insulation and as moisture-proofing for applications including roofs.

The 1960s heralded a number of major new market developments where alufoil's protective properties against light and oxygen were used to good effect. For example thin alufoil was used in conjunction with paper and PE to create a laminate for aseptic cartons (Tetra Brik). Originally conceived for use with UHT milk, the alufoil laminated carton has now established itself for applications including fruit juices, soups, yoghurt drinks and much more. Additionally thanks to its heat and moisture resistance alufoil started to be used to pack foodstuffs to be sterilised in autoclaves. And by the 1960s household foil was becoming increasingly accepted across the majority of European markets.

Another success story in the 1960s was the alufoil laminate tube, comprising plastic/paper/ alufoil, which conquered markets for goods such as toothpaste, cosmetic creams and pharmaceutical ointments.

Aluminium laminates were used increasingly for pharmaceutical products during the 1970s, where the resistance to water vapour and gas tight properties were used to good effect. In 1978 the first large-scale use of an aluminium-plastic laminate, for a well-known effervescent tablet for headaches, took place. And by the 1980s blister packs were starting to be introduced on a wide scale.

Indeed by the end of the 1990s alufoil was accepted as an innovative material for almost all packaging applications with expressions such as "foil-sealed for freshness" becoming commonplace on branded packs. Alufoil was also responsible for the growth of a new market for easy-open ‘gourmet' pet food containers.

It was the barrier properties of alufoil which were instrumental in its success up to the end of the 20th Century and this continues today. Setting it apart from other materials are its total block to light, moisture and aromas with a very thin layer of alufoil transforming the performance of a flexible packaging laminate.

Greatly assisting the growth of alufoil was the formation of the European Aluminium Foil Association in 1974 which has been instrumental in spreading the message to a wide audience, and growing its success into the 21st century.