aluminum foil manufacturers commonly use pure aluminum. In recent years it has become popular to add a variety of aluminum alloys engineered to add strength and reduce the thickness of the aluminum foil.
Once the alloy mixture is determined, it is melted and poured onto a cast and rolled to form a large sheet of aluminum foil. The rolling process is repeated until the desired thickness is reached. The main factors in reaching the desired thickness are roll pressure, mil speed, and rolling oils. As the aluminum foil is rolled into the desired thickness, it is spooled on large stock coils to hold the aluminum foil
From the large coils, the aluminum foil is unspooled, cut, and spooled onto smaller cardboard spools. Once the aluminum foil is spooled onto the smaller spools, it is placed into boxes and prepared for shipping. The roll width, length, and thickness determine the number of boxes per case, and cases per pallet.
For more information about the production of aluminum foil with illustrations and details about refining processes, visit aluminum.org.