Bare Aluminum Foil Alloy Comparison: 8011 vs. 1235 vs. 8079 (Which One Do You Need?)

Selecting the right alloy for bare aluminum foil (plain aluminum foil) is critical for downstream conversion, packaging integrity, and cost optimization. While 8011, 1235, and 8079 are the three most popular alloys in flexible packaging, their mechanical properties and barrier capabilities differ significantly.

Here is a performance comparison to help you choose the ideal alloy for your production requirements.

1. 1235 Aluminum Foil: High Purity & Superior Flexibility

With an aluminum content of no less than 99.35%, 1235 aluminum foil offers excellent electrical conductivity, high ductility, and superior dead-fold performance.

Tensile Strength: Moderate (75–105 MPa in O temper)

Elongation: High ductility, ideal for smooth folding

Best Applications: Cigarette inner liners, food lamination foil, cable shielding, and tape backing.

2. 8011 Aluminum Foil: Superior Mechanical Strength & Deep Drawing

Containing added Silicon (Si) and Iron (Fe) elements, 8011 aluminum foil delivers significantly higher tensile strength and puncture resistance compared to pure aluminum alloys.

Tensile Strength: High (95–130 MPa in O temper)

Barrier Performance: Excellent pinhole resistance in thicker gauges

Best Applications: Food containers, milk bottle caps, pharmaceutical closures, and household foil rolls.

Caption: High-tensile 8011 bare aluminum foil jumbo roll designed for container stamping and deep drawing.

3. 8079 Aluminum Foil: Ultra-Low Pinholes for Thin-Gauge Barrier Packaging

8079 aluminum foil is specifically engineered for ultra-thin flexible packaging (under 9 microns) where zero pinholes and maximum moisture barrier performance are required.

Tensile Strength & Elongation: High elongation and excellent resistance to tearing

Barrier Performance: Industry-leading moisture, oxygen, and light barrier at minimal thickness

Best Applications: Pharmaceutical blister packaging (PTP/Cold form foil), aseptic liquid packaging (Tetra Pak style), and high-barrier pouch lamination.

Alloy Selection Summary

Choose 1235 if you need high purity, maximum flexibility, and cost-effective food/cable lamination.

Choose 8011 if your process requires high strength, deep drawing, or rigid container forming.

Choose 8079 for ultra-thin pharmaceutical or aseptic packaging demanding strict pinhole control.

Looking for High-Quality Bare Aluminum Foil Jumbo Rolls?

We supply factory-direct 1235, 8011, and 8079 bare aluminum foil rolls in O, H18, and H22 tempers with Grade A degreasing. Contact our engineering sales team today for technical datasheets and free sample rolls!