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Main products: Aluminum foil roll rewinding machine, Aluminum foil container making machine,Aluminum foil container mold

Aluminum foil ---how to make

Background

Aluminum foil is made from an aluminum alloy which contains between 92 and 99 percent aluminum. Usually between 0.00017 and 0.0059 inches thick, foil is produced in many widths and strengths for literally hundreds of applications. It is used to manufacture thermal insulation for the construction industry, fin stock for air conditioners, electrical coils for transformers, capacitors for radios and televisions, insulation for storage tanks, decorative products, and containers and packaging. The popularity of aluminum foil for so many applications is due to several major advantages, one of the foremost being that the raw materials necessary for its manufacture are plentiful. Aluminum foil is inexpensive, durable, non-toxic, and greaseproof. In addition, it resists chemical attack and provides excellent electrical and non-magnetic shielding.

Shipments (in 1991) of aluminum foil totaled 913 million pounds, with packaging representing seventy-five percent of the aluminum foil market. Aluminum foil's popularity as a packaging material is due to its excellent impermeability to water vapor and gases. It also extends shelf life, uses less storage space, and generates less waste than many other packaging materials. The preference for aluminum in flexible packaging has consequently become a global phenomenon. In Japan, aluminum foil is used as the barrier component in flexible cans. In Europe, aluminum flexible packaging dominates the market for pharmaceutical blister packages and candy wrappers. The aseptic drink box, which uses a thin layer of aluminum foil as a barrier against oxygen, light, and odor, is also quite popular around the world.

Aluminum is the most recently discovered of the metals that modern industry utilizes in large amounts. Known as "alumina," aluminum compounds were used to prepare medicines in ancient Egypt and to set cloth dyes during the Middle Ages. By the early eighteenth century, scientists suspected that these compounds contained a metal, and, in 1807, the English chemist Sir Humphry Davy attempted to isolate it. Although his efforts failed, Davy confirmed that alumina had a metallic base, which he initially called "alumium." Davy later changed this to "aluminum," and, while scientists in many countries spell the term "aluminium," most Americans use Davy's revised spelling. In 1825, a Danish chemist named Hans Christian Ørsted successfully isolated aluminum, and, twenty years later, a German physicist named Friedrich Wohler was able to create larger particles of the metal; however, Wohler's particles were still only the size of pinheads. In 1854 Henri Sainte-Claire Deville, a French scientist, refined Wohler's method enough to create aluminum lumps as large as marbles. Deville's process provided a foundation for the modern aluminum industry, and the first aluminum bars made were displayed in 1855 at the Paris Exposition.

At this point the high cost of isolating the newly discovered metal limited its industrial uses. However, in 1866 two scientists working separately in the United States and France concurrently developed what became known as the Hall-Héroult method of separating alumina from oxygen by applying an electrical current. While both Charles Hall and Paul-Louis-Toussaint Héroult patented their discoveries, in America and France respectively, Hall was the first to recognize the financial potential of his purification process. In 1888

The Bayer process of refining bauxite consists of four steps: digestion, clarification, precipitation, and calcination. The result is a fine white powder of aluminum oxide.

he and several partners founded the Pittsburgh Reduction Company, which produced the first aluminum ingots that year. Using hydroelectricity to power a large new conversion plant near Niagara Falls and supplying the burgeoning industrial demand for aluminum, Hall's company—renamed the Aluminum Company of America (Alcoa) in 1907—thrived. Héroult later established the Aluminium-Industrie-Aktien-Gesellschaft in Switzerland. Encouraged by the increasing demand for aluminum during World Wars I and II, most other industrialized nations began to produce their own aluminum. In 1903, France became the first country to produce foil from purified aluminum. The United States followed suit a decade later, its first use of the new product being leg bands to identify racing pigeons. Aluminum foil was soon used for containers and packaging, and World War II accelerated this trend, establishing aluminum foil as a major packaging material. Until World War II, Alcoa remained the sole American manufacturer of purified aluminum, but today there are seven major producers of aluminum foil located in the United States.

Raw Materials

Aluminum numbers among the most abundant elements: after oxygen and silicon, it is the most plentiful element found in the earth's surface, making up over eight percent of the crust to a depth of ten miles and appearing in almost every common rock. However, aluminum does not occur in its pure, metallic form but rather as hydrated aluminum oxide (a mixture of water and alumina) combined with silica, iron oxide, and titania. The most significant aluminum ore is bauxite, named after the French town of Les Baux where it was discovered in 1821. Bauxite contains iron and hydrated aluminum oxide, with the latter representing its largest constituent material. At present, bauxite is plentiful enough so that only deposits with an aluminum oxide content of forty-five percent or more are mined to make aluminum. Concentrated deposits are found in both the northern and southern hemispheres, with most of the ore used in the United States coming from the West Indies, North America, and Australia. Since bauxite occurs so close to the earth's surface, mining procedures are relatively simple. Explosives are used to open up large pits in bauxite beds, after which the top layers of dirt and rock are cleared away. The exposed ore is then removed with front end loaders, piled in trucks or railroad cars, and transported to processing plants. Bauxite is heavy (generally, one ton of aluminum can be produced from four to six tons of the ore), so, to reduce

Continuous casting is an alternative to melting and casting aluminum. An advantage of continuous casting is that it does not require an annealing (heat treatment) step prior to foil rolling, as does the melting and casting process.

the cost of transporting it, these plants are often situated as close as possible to the bauxite mines.

The Manufacturing 
Process

Extracting pure aluminum from bauxite entails two processes. First, the ore is refined to eliminate impurities such as iron oxide, silica, titania, and water. Then, the resultant aluminum oxide is smelted to produce pure aluminum. After that, the aluminum is rolled to produce foil.

Refining — Bayer process

• 1 The Bayer process used to refine bauxite comprises four steps: digestion, clarification, precipitation, and calcination. During the digestion stage, the bauxite is ground and mixed with sodium hydroxide before being pumped into large, pressurized tanks. In these tanks, called digesters, the combination of sodium hydroxide, heat, and pressure breaks the ore down into a saturated solution of sodium aluminate and insoluble contaminants, which settle to the bottom.
• 2 The next phase of the process, clarification, entails sending the solution and the contaminants through a set of tanks and presses. During this stage, cloth filters trap the contaminants, which are then disposed of. After being filtered once again, the remaining solution is transported to a cooling tower.
• 3 In the next stage, precipitation, the aluminum oxide solution moves into a large silo, where, in an adaptation of the Deville method, the fluid is seeded with crystals of hydrated aluminum to promote the formation of aluminum particles. As the seed crystals attract other crystals in the solution, large clumps of aluminum hydrate begin to form. These are first filtered out and then rinsed.
• 4 Calcination, the final step in the Bayer refinement process, entails exposing the aluminum hydrate to high temperatures. This extreme heat dehydrates the material, leaving a residue of fine white powder: aluminum oxide.

Smelting

• 5 Smelting, which separates the aluminum-oxygen compound (alumina) produced by the Bayer process, is the next step in extracting pure, metallic aluminum from bauxite. Although the procedure currently used derives from the electrolytic method invented contemporaneously by Charles Hall and Paul-Louis-Toussaint Héroult in the late nineteenth century, it has been modernized. First, the alumina is dissolved in a smelting cell, a deep steel mold lined with carbon and filled with a heated liquid conductor that consists mainly of the aluminum compound cryolite.
• 6 Next, an electric current is run through the cryolite, causing a crust to form over the top of the alumina melt. When additional alumina is periodically stirred into the mixture, this crust is broken and stirred in as well. As the alumina dissolves, it electrolytically decomposes to produce a layer of pure, molten aluminum on the bottom of the smelting cell. The oxygen merges with the carbon used to line the cell and escapes in the form of carbon dioxide.
• 7 Still in molten form, the purified aluminum is drawn from the smelting cells, transferred into crucibles, and emptied into furnaces. At this stage, other elements can be added to produce aluminum alloys with characteristics appropriate to the end product, though foil is generally made from 99.8 or 99.9 percent pure aluminum. The liquid is then poured into direct chill casting devices, where it cools into large slabs called "ingots" or "reroll stock." After being annealed—heat treated to improve workability—the ingots are suitable for rolling into foil.
  

  Foil is produced from aluminum stock by rolling it between heavy rollers. Rolling produces two natural finishes on the foil, bright and matte. As the foil emerges from the rollers, circular knives cut it into rectangular pieces.
• An alternative method to melting and casting the aluminum is called "continuous casting." This process involves a production line consisting of a melting furnace, a holding hearth to contain the molten metal, a transfer system, a casting unit, a combination unit consisting of pinch rolls, shear and bridle, and a rewind and coil car. Both methods produce stock of thicknesses ranging from 0.125 to 0.250 inch (0.317 to 0.635 centimeter) and of various widths. The advantage of the continuous casting method is that it does not require an annealing step prior to foil rolling, as does the melting and casting process, because annealing is automatically achieved during the casting process.

Rolling foil

• 8 After the foil stock is made, it must be reduced in thickness to make the foil. This is accomplished in a rolling mill, where the material is passed several times through metal rolls called work rolls. As the sheets (or webs) of aluminum pass through the rolls, they are squeezed thinner and extruded through the gap between the rolls. The work rolls are paired with heavier rolls called backup rolls, which apply pressure to help maintain the stability of the work rolls. This helps to hold the product dimensions within tolerances. The work and backup rolls rotate in opposite directions. Lubricants are added to facilitate the rolling process. During this rolling process, the aluminum occasionally must be annealed (heat-treated) to maintain its workability.
• The reduction of the foil is controlled by adjusting the rpm of the rolls and the viscosity (the resistance to flow), quantity, and temperature of the rolling lubricants. The roll gap determines both the thickness and length of the foil leaving the mill. This gap can be adjusted by raising or lowering the upper work roll. Rolling produces two natural finishes on the foil, bright and matte. The bright finish is produced when the foil comes in contact with the work roll surfaces. To produce the matte finish, two sheets must be packed together and rolled simultaneously; when this is done, the sides that are touching each other end up with a matte finish. Other mechanical finishing methods, usually produced during converting operations, can be used to produce certain patterns.
• 9 As the foil sheets come through the rollers, they are trimmed and slitted with circular or razor-like knives installed on the roll mill. Trimming refers to the edges of the foil, while slitting involves cutting the foil into several sheets. These steps are used to produce narrow coiled widths, to trim the edges of coated or laminated stock, and to produce rectangular pieces. For certain fabricating and converting operations, webs that have been broken during rolling must be joined back together, or spliced. Common types of splices for joining webs of plain foil and/or backed foil include ultrasonic, heat-sealing tape, pressure-sealing tape, and electric welded. The ultrasonic splice uses a solid-state weld—made with an ultrasonic transducer—in the overlapped metal.

Finishing processes

• 10 For many applications, foil is used in I V / combination with other materials. It can be coated with a wide range of materials, such as polymers and resins, for decorative, protective, or heat-sealing purposes. It can be laminated to papers, paperboards, and plastic films. It can also be cut, formed into any shape, printed, embossed, slit into strips, sheeted, etched, and anodized. Once the foil is in its final state, it is packaged accordingly and shipped to the customer.

Quality Control

In addition to in-process control of such parameters as temperature and time, the finished foil product must meet certain requirements. For instance, different converting processes and end uses have been found to require varying degrees of dryness on the foil surface for satisfactory performance. A wettability test is used to determine the dryness. In this test, different solutions of ethyl alcohol in distilled water, in increments of ten percent by volume, are poured in a uniform stream onto the foil surface. If no drops form, the wettability is zero. The process is continued until it is determined what minimum percent of alcohol solution will completely wet the foil surface.

Other important properties are thickness and tensile strength. Standard test methods have been developed by the American Society For Testing and Materials (ASTM). Thickness is determined by weighing a sample and measuring its area, and then dividing the weight by the product of the area times the alloy density. Tension testing of foil must be carefully controlled because test results can be affected by rough edges and the presence of small defects, as well as other variables. The sample is placed in a grip and a tensile or pulling force is applied until fracture of the sample occurs. The force or strength required to break the sample is measured.

The Future

The popularity of aluminum foil, especially for flexible packaging, will continue to grow. Four-sided, fin-sealed pouches have gained wide popularity for military, medical, and retail food applications and, in larger sizes, for institutional food service packs. Pouches have also been introduced for packaging 1.06 to 4.75 gallons (4-18 liters) of wine for both retail and restaurant markets, and for other food service markets. In addition, other products continue to be developed for other applications. The increase in popularity of microwave ovens has resulted in the development of several forms of aluminum-based semi-rigid containers designed specifically for these ovens. More recently, special cooking foils for barbecuing have been developed.

However, even aluminum foil is being scrutinized in regard to its environmental "friendliness." Hence, manufacturers are increasing their efforts in the recycling area; in fact, all U.S. foil producers have begun recycling programs even though aluminum foil's total tonnage and capture rate is much lower than that of the easy-to-recycle aluminum cans. Aluminum foil already has the advantage of being light and small, which helps reduce its contribution to the solid waste stream. In fact, laminated aluminum foil packaging represents just 17/lOOths of one percent of the U.S. solid waste.

For packaging waste, the most promising solution may be source reduction. For instance, packaging 65 pounds (29.51 kilograms) of coffee in steel cans requires 20 pounds (9.08 kilograms) of steel but only three pounds (4.08 kilograms) of laminated packaging including aluminum foil. Such packaging also takes up less space in the landfill. The Aluminum Association's Foil Division is even developing an educational program on aluminum foil for universities and professional packaging designers in order to help inform such designers of the benefits of switching to flexible packaging.

Aluminum foil also uses less energy during both manufacturing and distribution, with in-plant scrap being recycled. In fact, recycled aluminum, including cans and foil, accounts for over 30 percent of the industry's yearly supply of metal. This number has been increasing for several years and is expected to continue. In addition, processes used during foil manufacturing are being improved to reduce air pollution and hazardous waste.

Where To Learn More

Books

Aluminum Foil. The Aluminum Association. 1981

The advantages of aluminium foils

The foil applied to food and beverage packaging saves more resources than are needed for production. Several life cycle analysis (LCA) show that the foil used for packaging and in the home account for less than 10% of the environmental impact in the life cycle of a product: production, preparation and consumption.

Insulating protection:

The total insulation foil against light, moisture and gases is the main reason I used flexible laminate packaging for food, beverage and technical applications. Even if it is very thin, ensures perfect protection and preservation of aroma and product features.You can help extend the life of delicate products for many months, even years, while fully preserving their precious aroma. By allowing the products are retained for long periods without refrigeration, packaging in foil helps prevent deterioration and can provide great energy savings.

Mechanical Properties:

Lightweight but strong, the feature that makes the single foil is its ability to hold its shape, a quality that makes it ideal for packaging and re-packaging of products with all kinds of ways, and that minimizes the need for adhesives or sealed. Thanks to its malleability can be easily deformed without losing its insulating capacity, making it an ideal material for creating very thin sheets, in combination with other flexible substrates are used in a variety of markets and, therefore, a resource-saving Again.

Plasticity and strength:

When pressed into a mold, the foil memorizes their shape, especially where it folds and edges. Thus, you can select the shape, thickness, alloy and temper required to create the desired performance characteristics.

Lightness and space utilization:

The transport and storage can significantly cheaper thanks to the lightness and flat or rolled format of empty containers, and in the case of aluminum foil containers, by stacking forms, especially suitable for cartridge filling machines . The foil helps to save resources during packaging and transporting products and waste. By allowing the products are retained for long periods without refrigeration, packaging in foil provides great energy savings, since thanks to its use of space efficiently when storing and displaying items on shelves, thus enabling greater energy savings and costs. The foil is effective, saves weight and minimizes the amount of packaging material required.

Structural stability:

In light structures honeycomb, aluminum foil provides the necessary rigidity and stability enabling architects to ease the construction of structures and foundations, and engineers save weight in all types of vehicles - boats, planes, trucks and cars.

Recycling:

Aluminium is 100% recyclable, with no expiration date or loss of quality. The process of recycling aluminum requires 95% less energy compared to its production from bauxite ore, leading to a huge reduction in emissions. Modern techniques allow the extraction recycling aluminum paper and recycle household waste at a fraction of its original energy cost.

Recovery:

If the foil is not recycled, but is subjected to a smelting process in a furnace, the thin aluminum sheet is oxidized largely and releases energy that can be recovered. Moreover, the remaining aluminum unoxidized still be drawn from the furnace bottom ash and subsequently used for recycling.

Heating output:

The foil material is highly conductive of heat. Supports all temperature variations experienced by packages, from well below freezing to extremely hot temperatures, such as for baking or roasting, without distorting, melting or face the risk of suddenly cracking. The foil also dissipates heat quickly and is ideal for sterilization in autoclaves and heat-sealing process. You can help minimize sealing times and even the temperature gradient within the containers and flexible packaging, protecting product quality and saving energy. Its thermal conductivity achieved minimize processing time, cooling and reheating. This is vital for the proper functioning of the electrical system of a vehicle and to ensure the comfort of the driver and passengers, as foil fins in the heat exchanger provide cooling and heating as required. Thanks to its lightweight, aluminum foil has become an automatic choice in this field.

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Cooking and heating in any way:

Preserved foods in aluminum foil dishes can be cooked or reheated in convection ovens, microwave or fan or systems to "bath".
Foil containers help to save time and resources during the preparation of food.

Hygiene:

Once produced, the foil is completely sterile due to the high temperature reached in the process of cooking. It is a safe material for use in contact with foodstuffs because it allows the creation houses or bacteria.

Product Safety and Integrity:

The foil is a safe material for use in contact with foodstuffs. The bare foil does not react with the majority of the food. In many applications, the foil does not come into direct contact with the product as it is processed with other materials to form a laminate.Moreover, it is an ideal protection against deterioration of the product and helps to combat counterfeiting.

Decorative Possibilities:

The glossy or matte metallic foil, along with its compatibility with all printing techniques, offers designers enormous scope for creating stunning design packaging graphics and great presence during his presentation, which gives the brand identity .

reflection:

The foil reflects up to 98% of light and infrared heat. In addition, the glossy surface shows a low-heat, saving energy in the process of isolation. Its applications extend as insulation fire protection. The firewall screens for vehicles and vessels, or doors and building panels fire resistant foil dissipates heat and blocks access to the necessary oxygen to fan the flames.

Conductivity:

Also foil shielding against magnetic and broadcasts radio frequency. In fiber optic cables, the foil is used as an indicator to check the integrity of the connections. In a network of wires, the electrical conductivity of aluminum can verify the integrity of the circuit.

Who Knew? Household Uses for Aluminum Foil -- It's a nice article.

We all know you can protect cookware with aluminum foil and use it to store leftovers, but did you know you could use it to fix a broken toy; or to protect silverware from tarnish? There are actually several things you can do or fix around the house with a little bit of aluminum foil.

Fixing a broken toy:  If you have a battery operated toy that is missing the spring that holds the batteries in place, you can use a small ball of aluminum foil in place of the spring to hold batteries in place, it will conduct the electricity the same way the missing spring would. 

Keep silverware from tarnishing: By simply storing your silverware on top of a piece of aluminum foil, it will protect it from tarnishing.  The aluminum foil actually attracts the toxins that make silver tarnish.  Furthermore, store your silver jewelry in a Ziploc bag with a piece of aluminum foil to keep it from tarnishing.

Polish your silver: Line a pan with aluminum foil, fill with cold water, and add a tablespoon of salt.  Allow silver to sit in the mix for a few minutes, remove, and rinse.  The aluminum foil will act as a catalyst for ion exchange and the tarnish will transfer from your silver to the salt water mix. 

Ironing:  Cover your ironing board in aluminum foil before you iron clothes to help get the wrinkles out twice as fast.  The aluminum foil heats up, basically allowing you to iron both sides of your clothes at once.  This trick can save you time and energy. Additionally, if your iron is dirty from using too much starch you can clean it by running the hot iron over a piece of aluminum foil a few times.    

Brown Sugar Block: Ever go to use your brown sugar only to find it is one giant block of brown sugar?  Wrap the block of brown sugar in some aluminum foil and bake it at 350°F for five minutes.  This will help remove the moisture and have your brown sugar back to its old self again. 

Sharpen scissors:  If your scissors are dull, you can sharpen them by placing several sheets of aluminum foil on top of each other and then cutting through the layers.  Repeat this step a few times and voila your scissors will be like new. 

Deter rodents:  Having a hard time keeping those pesky rodents out of your garden?  Shred pieces of aluminum foil and mix the pieces in with the mulch in your garden.  The horrid feeling of aluminum foil between their teeth will deter rodents. 

Give houseplants a boost:  If your houseplants are not getting enough sunlight, line a table with aluminum foil shiny side up.  The aluminum foil will reflect the light maximizing any amount of sunlight.

Grilling: Aluminum foil is great for grilling.  If you want to get your grill grate extra hot, cover it with a piece of aluminum foil ten minutes before cooking.  After grilling, cover the grate with the same piece of aluminum foil, close the lid and leave for fifteen minutes.  The residue from the food will have turned to ash making clean up a breeze. 

See more in the: 
The aluminum foil container mold , aluminum foil container machine, aluminum foil rewinding machine, paper cup forming machine, paper bowl forming machine , aluminum coil composite panel machine,and yogurt lid die cutting machine.
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Function about Aluminum foil roll

Household Tips

 

For this week, I’m concentrating on solutions to problems most of us have had to deal with at one time or another.  Let’s get started…

Someone is useful to you.

Aluminum Foil

• Are the chrome hubcaps on your car looking a little sad?  Take a piece of aluminum foil with the shiny side facing out and polish your hubcaps.  I tried this a few years ago for the first time and now I’m hooked.  This really works!

Baby Powder

• Got squeaky floorboards?  Sprinkle some baby powder on your wood floors and sweep it back and forth working it into the cracks.  Sweep away excess.  Voila!  No more squeaks!

Carpet Scraps

• If your car doesn’t have quite as much room in the garage as you would like, then there probably have been times you’ve accidentally hit the garage wall, possibly giving your car a ding or two.  Hang a patch of carpet on the wall in the garage where the door opens, and no more worries.
• Put one of the larger left over pieces of carpet by the door in the garage that leads into your home. This area gets lots of abuse. Your floors will thank you.

Cooking Oil Spray

• Don’t you just hate it when grass builds up on your mower blades? Try spraying the blades of your lawn mower with cooking oil spray. Problem solved.
• Have you ever stored tomato based items in a plastic container, only to find out when you go to clean it, it’s now red?  Spritz the inside of plastic containers before storing food containing tomato sauce to resolve this problem.

Denture Tablets

I have been making good use of these for years, and trust me, I have all my teeth 

• Drop a couple of tablets into a slow drain and run some hot water to quickly clear the drain.
• Denture tablets make great jewelry cleaners too!  Put a tablet in a glass of water and drop in your jewelry for a few minutes. Rinse and then admire your puurdy bling.

Paintbrushes

• For an inexpensive alternative to basting brushes, use a new natural bristle paintbrush for basting, buttering and greasing everything from muffin tins to barbecue racks.

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Aluminum foil roll and container---a practical purpose or use

Aluminum foil roll and container--a practical purpose or use

Aluminum foil roll

Aluminum foil container 

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