The Manufacturing Odyssey – Engineering Excellence in Foil Container Production

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The metamorphosis of aluminum ingots into high-performance foil containers represents a feat of materials engineering and precision manufacturing. This process bridges metallurgical science, industrial automation, and food safety compliance to create sustainable, high-barrier packaging solutions.


Section 1: Raw Material Selection & Metallurgical Foundations

  • Alloy Specifications

    Alloy Series Key Elements Application Suitability
    8000-series Fe 0.5-1.0%, Mn <0.3% Food containers (pH>4.0)
    3000-series Mn 1.0-1.5%, Mg 0.8-1.3% High-strength trays
  • Ingot Quality Control

    • Hydrogen content: <0.15 ml/100g Al

    • Inclusion size: ≤20 μm


Section 2: Precision Rolling – From Slab to Foil

  • Hot Rolling Process

    • Temperature: 480-520°C

    • Thickness reduction: 600mm → 6mm in 5 passes

  • Cold Rolling Critical Parameters

    Stage Entry Thickness Exit Thickness Reduction %
    Breakdown 6 mm 0.7 mm 88%
    Finishing 0.7 mm 0.05-0.2 mm 71-93%
  • Annealing Protocols
    Batch annealing at 340-380°C for 8-12 hours to restore ductility


Section 3: Container Forming Technologies

  • Mechanical Pressing

    • Force range: 200-800 tons

    • Stroke speed: 30-70 cycles/minute

  • Impact Extrusion

    • Pressure: 1,500-2,500 bar

    • Wall thickness tolerance: ±5%

  • Critical Tooling Specifications

    • Tool steel hardness: 58-62 HRC

    • Surface finish: Ra ≤0.2 μm


Section 4: Quality Assurance & Performance Testing

  • Barrier Property Validation

    Test Standard Requirement
    Water Vapor Transmission ASTM E96 <0.01 g/m²/day
    Oxygen Permeability ASTM D3985 <0.05 cc/m²/day
  • Mechanical Strength Testing

    • Stacking resistance: ≥150 kg for 24h

    • Edge crush resistance: ≥180 N


Section 5: Surface Engineering & Coatings

  • Lacquer Application Systems

    Coating Type Thickness Acid Resistance
    Epoxy-phenolic 3-5 g/m² pH ≥3.0
    Polyester 4-6 g/m² pH ≥2.5
  • Corrosion Protection
    Chromating treatment: 10-50 mg/m² Cr⁶⁺

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