Custom Aluminum Laminate for OEM Flexible Packaging

Custom Aluminum Laminate for OEM Flexible Packaging

Custom aluminum laminate combines aluminum foil with functional polymer films such as PET, PE, PA Nylon, CPP, PP and EVOH to create application-specific multilayer materials for flexible packaging, industrial protection and engineered composite applications.

Instead of using one standard laminate for every application, the layer structure can be selected according to required oxygen and moisture barrier, heat-sealing conditions, puncture resistance, printing, filling process, thermal treatment, roll dimensions and final product requirements.

Available structures include PET/AL/PE, PET/AL/CPP, PET/AL/PA/PE, PA/AL/PP, AL/PE/AL and customized multilayer constructions. Aluminum foil thickness ranges from 6μm to 50μm, total laminate thickness from 50μm to 350μm, and finished width from 100mm to 2200mm.

Request a Custom Laminate Recommendation

Technical Specifications

Send Your Material Specification

Custom Laminate Engineering

Application-Specific Layer Design

The laminate structure can be selected according to the packed product, expected shelf life, filling process, storage environment, sealing equipment and mechanical demands rather than relying on a single standard construction.

Aluminum Foil Gauge Selection

Aluminum foil thickness can be selected within the 6-50μm range according to barrier requirements, flex durability, forming behavior, stiffness and overall laminate design.

Heat-Seal Layer Selection

PE, CPP, PP or another compatible sealant can be selected according to filling temperature, seal-window requirements, product contact, packaging machinery and thermal-processing conditions.

Barrier Performance Design

Where barrier performance is critical, provide numerical OTR and WVTR targets together with the required test temperature, relative humidity and test method. Final barrier performance depends on the entire laminate, foil integrity and finished package seals.

Roll Configuration

Roll width, roll length, core diameter, maximum roll diameter, winding direction, splice allowance and repeat length can be coordinated with the buyer's printing, laminating, pouch-making or form-fill-seal equipment.

Lamination and Converting Capabilities

Dry Lamination

Dry lamination can be used for compatible multilayer structures requiring controlled bond strength, barrier performance and flexible packaging conversion.

Extrusion Lamination

Extrusion lamination can be selected where a polymer layer or bonding layer needs to be integrated with foil or other substrates according to the required composite construction.

Solvent-Based and Solvent-Free Lamination

The lamination method and adhesive system should be selected according to substrate compatibility, curing requirements, heat resistance, bond performance and the intended packaging application.

Functional Coating and Surface Treatment

Functional surface treatments can be evaluated where the application requires improved printing, bonding, surface appearance or additional process compatibility.

Gravure Printing

Custom gravure printing up to 10 colors is available for branded rollstock and flexible packaging. Artwork, print repeat, color reference, surface finish and winding direction should be confirmed before production.

Available Material Structures

PET / AL / PE

PET/AL/PE combines a printable and dimensionally stable PET outer layer, aluminum foil barrier and PE sealing layer. It can be used for suitable food, powder, coffee, pharmaceutical, industrial and general high-barrier packaging applications.

PET / AL / CPP

PET/AL/CPP provides a printable outer surface, foil barrier and CPP sealant layer. The exact CPP grade should be selected according to heat-seal and thermal-processing requirements.

PET / AL / PA / PE

The addition of PA Nylon increases puncture resistance and mechanical durability. This structure can be considered for vacuum packaging, heavy-duty flexible packaging and products requiring greater resistance to handling damage.

PA / AL / PP

PA/AL/PP combines mechanical reinforcement, aluminum barrier and polypropylene sealing functionality. The exact PA, adhesive and PP grades must be matched to the intended forming, sealing and product-contact requirements.

AL / PE / AL Composite

Double-sided aluminum composite structures can be developed as moisture- and vapor-barrier facings for selected insulation, HVAC and industrial composite systems. Overall thermal performance depends on the complete insulation assembly rather than the aluminum laminate alone.

Customized Multilayer Structure

Additional PET, PA, EVOH, PE, CPP, PP, foil and functional layers can be combined where the required construction has been reviewed for barrier, mechanical, sealing and processing performance.

Selecting the Right Aluminum Laminate

High Barrier Performance

Oxygen Barrier

Aluminum foil provides a strong oxygen barrier when the foil and laminate remain intact. Where oxygen transmission affects shelf life or product stability, the required OTR should be defined numerically.

Moisture Barrier

Foil-based laminates can provide strong protection against water vapor. For controlled applications, specify the required WVTR and test conditions instead of relying only on descriptions such as “high barrier.”

Light Protection

Opaque aluminum foil helps protect light-sensitive products by preventing light transmission through the laminate.

Aroma and Odor Protection

Suitable foil laminates can help reduce aroma loss and external odor ingress. Finished-package performance also depends on seal integrity, closures and package geometry.

Food and Beverage Packaging

Dry Food, Coffee and Powder Packaging

PET/AL/PE and related structures can be developed for coffee, snacks, powders, ingredients and other oxygen- or moisture-sensitive products requiring printed high-barrier flexible packaging.

Vacuum Packaging

Nylon-reinforced foil laminates can be selected for suitable vacuum-packed food where puncture resistance and reliable seals are required.

Retort Packaging

High-temperature sterilization requires a specifically designed retort-grade laminate. Provide actual sterilization temperature, time, pressure and food composition so that the adhesive and sealant layers can be selected and validated.

Aseptic Packaging Projects

For aseptic packaging, the complete material structure must be evaluated with the filling, sterilization and sealing system. General aluminum laminates should not be assumed to meet aseptic-process requirements without project-specific validation.

Pharmaceutical and Healthcare Applications

High-barrier aluminum laminates can be evaluated for pharmaceutical powders, nutraceutical products, medical consumables and other healthcare packaging where the selected materials, cleanliness, migration performance and documentation meet the intended product and destination-market requirements.

Buyers should specify whether the material will contact the product directly and identify any required pharmaceutical, food-contact, migration or sterilization documentation before laminate development.

Industrial and Equipment Protection

Foil laminates can be developed as high-barrier wrapping, liners or protective packaging for moisture-sensitive equipment, components and industrial materials during storage and export transportation.

Where corrosion prevention is required, the complete packaging system—including humidity control, desiccant, VCI material where applicable and sealing method—should be specified rather than relying on aluminum laminate alone.

Insulation and HVAC Composite Applications

AL/PE/AL and related aluminum composite structures can be evaluated as foil facings, vapor-barrier layers or protective surfaces in suitable insulation and HVAC systems.

Thermal performance should be determined from the complete insulation assembly, including insulation core, air space, installation method and applicable building or equipment requirements.

Lithium Battery Pouch Laminate Projects

Lithium-ion pouch-cell packaging requires a dedicated aluminum laminate construction designed for deep drawing, moisture barrier, electrical insulation, heat sealing and electrolyte resistance.

Battery pouch laminates commonly use Nylon, aluminum foil and specially selected polypropylene-based sealing layers. Battery-grade projects should therefore be treated as dedicated material developments rather than using a general flexible-packaging laminate without qualification.

For a battery pouch project, provide the required forming depth, total laminate thickness, aluminum foil gauge, electrolyte system, heat-seal conditions, laminate bond requirements, surface properties and applicable cell-manufacturer specification for technical review.

Discuss an Engineered Laminate Project

OEM and Private-Label Manufacturing

Custom Specifications

Material construction, aluminum foil gauge, total thickness, roll dimensions, sealant layer and surface requirements can be produced to an agreed specification.

Private-Label Production

Private-label production can be coordinated for distributors, converters and packaging brands requiring customized product identification, labels and export packaging.

Custom Gravure Printing

Up to 10-color gravure printing is available according to approved artwork, print repeat, color standard and roll configuration.

Trial and Production Orders

Trial quantities and commercial production volumes can be discussed according to material availability, laminate complexity, printing cylinder requirements and project scale.

Custom Laminate Development Process

1. Application Review

Provide the packed product or industrial application, process conditions, required shelf life, storage environment and any regulatory or technical requirements.

2. Structure Selection

The aluminum foil thickness, polymer layers, adhesive system, sealant and total gauge are reviewed against barrier, mechanical and processing requirements.

3. Sample and Trial Evaluation

Where required, representative material can be evaluated for converting, sealing, filling, forming, thermal processing or other application-specific tests before commercial production.

4. Specification Approval

The agreed structure, total thickness, width, roll configuration, printing, surface condition and test requirements should be confirmed before production.

5. Commercial Production

Commercial production follows the approved material and roll specification, with required inspection items confirmed as part of the order.

Quality Control

Thickness and Dimensional Inspection

Aluminum foil gauge, total laminate thickness, roll width and other agreed dimensions can be checked according to the approved specification.

Lamination Bond and Peel Strength

Interlayer bond and peel requirements should be selected according to the laminate construction, converting process and final application.

Heat-Seal Performance

Heat-seal strength and sealing conditions can be evaluated according to the selected PE, CPP, PP or specialized sealant layer.

OTR and WVTR

Where oxygen or moisture transmission is a contractual requirement, target values and test conditions should be agreed before production.

Printing and Surface Inspection

Printed products can be inspected for approved artwork, color consistency, registration, surface appearance and other agreed visual requirements.

Roll Quality

Roll winding, edges, splices, core condition and surface cleanliness can be controlled according to the buyer's converting requirements.

Packaging and Delivery

Aluminum composite materials can be supplied in roll form with customized export packaging. Eye-to-sky, eye-to-wall, wooden case, pallet and moisture-resistant packaging can be selected according to roll size, handling method and transportation requirements.

Production and delivery schedules are confirmed according to laminate structure, printing requirements, order quantity, trial requirements and manufacturing schedule.

Wooden Case Packing

Pallet Coil Packing

Aluminum Foil Barrier Laminate

How to Specify a Custom Aluminum Laminate

Provide the Final Application

Identify whether the material is for food packaging, vacuum packaging, retort processing, pharmaceutical packaging, industrial protection, insulation facing, electronics or another engineered application.

Provide the Existing Structure if Known

If an existing laminate has already been approved, provide the full layer sequence and individual material gauges. If not, provide the required performance targets.

Specify Barrier Requirements

Provide OTR, WVTR, light-barrier or other required barrier properties together with applicable test conditions.

Specify Processing Conditions

State filling temperature, vacuum level, sterilization temperature and time, forming requirements, sealing conditions or other relevant production parameters.

Provide Roll Specifications

Provide width, roll length or diameter, core size, winding direction, repeat length, maximum roll weight and quantity.

Provide Printing Requirements

For printed laminate, provide artwork, number of colors, print repeat, matte or glossy requirements and approved color references.

Identify Regulatory Requirements

State the destination market and any required food-contact, pharmaceutical, industrial or other regulatory documentation before material selection.

Start Your Custom Laminate Project

Frequently Asked Questions

What is a custom aluminum laminate?

It is a multilayer composite combining aluminum foil with one or more polymer films or functional layers selected according to required barrier, mechanical, sealing, printing and processing performance.

Which laminate structures are available?

Available structures include PET/AL/PE, PET/AL/CPP, PET/AL/PA/PE, PA/AL/PP, AL/PE/AL and customized multilayer constructions.

What aluminum foil thicknesses are available?

The listed aluminum foil thickness range is 6μm to 50μm, subject to the required laminate structure and application.

What total laminate thicknesses are available?

Total laminate thickness can range from approximately 50μm to 350μm depending on the selected layers and application.

What is the maximum width?

The listed width range is 100mm to 2200mm. Actual availability should be confirmed for the selected structure and gauge.

Can you customize OTR and WVTR performance?

Structures can be selected according to target barrier performance. Provide the required OTR and WVTR together with the specified test temperature, humidity and method.

Can the laminate be used for vacuum packaging?

Yes. Nylon-reinforced structures such as PET/AL/PA/PE can be evaluated where high barrier, puncture resistance and vacuum seal performance are required.

Can it be used for retort packaging?

Retort applications require a specifically selected high-temperature laminate, adhesive and sealant layer. Provide the actual sterilization temperature, holding time, pressure and packed product before structure confirmation.

Can PET/AL/PA/PE automatically be used for retort pouches?

No. A standard PE-sealed vacuum laminate should not automatically be treated as retort suitable. High-temperature applications require a specifically qualified adhesive and sealant construction.

Can aluminum laminate be used for aseptic packaging?

A custom laminate can be evaluated for an aseptic packaging project, but the complete structure must be validated with the sterilization, filling and sealing process used by the packaging system.

Can you produce food-contact laminate?

Food-contact material options are available. The destination market, product type, contact conditions and required compliance documents should be stated before production.

Can it be used for pharmaceutical packaging?

High-barrier structures can be evaluated for suitable pharmaceutical and healthcare packaging when the required materials, cleanliness, migration performance and documentation meet the intended application.

Can the same laminate be used for lithium battery pouch cells?

Not automatically. Lithium-ion pouch cells require dedicated aluminum laminate with controlled deep-drawing, barrier, electrical insulation, heat-sealing and electrolyte-resistance properties. Battery-grade projects should be specified separately.

Can custom gravure printing be supplied?

Yes. Gravure printing up to 10 colors is available according to artwork, print repeat and production requirements.

Do you support OEM and private-label orders?

Yes. OEM, ODM, private-label production, customized specifications, printing and export packaging can be coordinated according to the approved project requirements.

Can trial quantities be produced?

Trial quantities can be discussed according to material availability, structure complexity, printing requirements and required converting setup.

What is the production lead time?

Lead time depends on laminate structure, printing cylinders, material availability, sample approval, order quantity and production schedule. The confirmed delivery time should be stated in the commercial quotation.

What information should I provide for a quotation?

Please provide the final application, existing laminate structure if available, aluminum foil thickness, total thickness, width, roll length or diameter, core size, winding direction, quantity, OTR/WVTR requirements, heat-seal layer, printing details, processing temperature, sterilization conditions if applicable, regulatory requirements and delivery destination.

Request a Custom Aluminum Laminate Quote

If you require a customized aluminum laminate for flexible packaging, vacuum or retort packaging, pharmaceutical products, industrial protection, insulation systems or another engineered composite application, send us your required structure, performance targets, dimensions, processing conditions and order quantity for review and quotation.

Contact Us for Custom Pricing