8011 vs 1235 Aluminum Foil: Which is Superior for Flexible Packaging?
Introduction: Two Workhorses of the Packaging Industry
When it comes to flexible packaging, two aluminum foil grades dominate the conversation: 8011 and 1235. Both are widely used across food packaging, pharmaceutical blister packs, and industrial applications. Yet they serve distinctly different roles. One is the high‑purity, ultra‑flexible specialist for demanding forming operations; the other is the versatile, cost‑effective workhorse that balances strength, pinhole resistance, and processability .
Understanding these differences is essential for selecting the right material for your packaging application—whether you are sealing yogurt cups, wrapping chocolate, or protecting sensitive pharmaceuticals.
Chemical Composition: The Purity vs. Strength Trade‑off
The fundamental difference between 8011 and 1235 lies in their alloy composition.
1235 Aluminum (1xxx Series)
●Aluminum content ≥99.35% — high purity commercial aluminum
●Very low impurity levels: Si+Fe ≤0.65%, other elements ≤0.05% each
●Emphasis on purity and ductility over strength
8011 Aluminum (8xxx Series)
●Al‑Fe‑Si alloy: Si 0.50‑0.90%, Fe 0.60‑1.00%
●Alloying elements improve strength, stability, and pinhole resistance
●Lower purity than 1235 but superior mechanical performance
| Element |
1235 | 8011 |
| Al Content | ≥99.35% | Balance (approx. 98%) |
| Silicon (Si) | ≤0.10% | 0.50‑0.90% |
| Iron (Fe) | ≤0.40% | 0.60‑1.00% |
| Manganese (Mn) | ≤0.05% | ≤0.20% |
Mechanical Properties: Strength vs. Flexibility
The compositional differences translate directly into distinct mechanical performance characteristics.
| Property |
1235‑O | 8011‑O | Practical Meaning |
| Tensile Strength | 45‑80 MPa | 70‑110 MPa | 8011 is significantly stronger |
| Yield Strength | ≤30 MPa | 30‑60 MPa | 8011 holds shape better during processing |
| Elongation | 1‑3% | 2‑5% | 1235 has slightly lower ductility |
| Pinhole Resistance | Moderate | Excellent | 8011 provides better barrier integrity |
| Surface Purity | Excellent | Good | 1235 offers cleaner, brighter surfaces |
What this means:
8011 delivers higher strength, better tear resistance, and superior pinhole control — essential for pharmaceutical blister packaging and high‑speed converting lines
1235 provides excellent flexibility and surface purity, making it ideal for deep‑draw applications like complex yogurt cup seals or candy wrappers where pure surface finish is critical
Formability: The Deep Drawing Difference
Both alloys are supplied in the O temper (fully annealed, soft) for packaging applications, but their forming behavior differs.
1235‑O: The higher purity and softer condition give 1235 exceptional ductility, making it easier to deep‑draw into complex shapes . It is often used for packaging requiring deep drawing, such as complex yogurt cup seals or jelly lids . However, its lower strength may require careful evaluation based on production conditions .
8011‑O: While slightly less formable than 1235, 8011 offers a better balance of strength and ductility. The addition of Fe and Si improves stability and resistance to pinholing, especially crucial for slightly thicker container and lid stock . It is the preferred choice for PTP blister packaging, lidding for food containers, and applications where both formability and barrier protection are important .
Barrier Performance: Protecting Your Product
The primary function of flexible packaging foil is to protect contents from moisture, oxygen, and light.
Both grades offer excellent barrier properties:
●Water vapor transmission rate ≤0.1 g/(m²·24h)
●Oxygen transmission rate effectively zero
●100% light opacity
However, 8011 has a critical advantage: pinhole resistance. Pinholes are microscopic holes through the foil that compromise the barrier. The higher strength and refined microstructure of 8011 result in very low pinhole counts, making it the preferred choice for pharmaceutical blister packaging where even a single pinhole can compromise drug stability . 1235, with its slightly lower strength, is more susceptible to pinhole formation.
Applications: Choosing the Right Grade
Choose 8011 Aluminum Foil When:
Pharmaceutical Packaging — PTP blister packs, pharmaceutical lidding, and sealing films. The zero‑pinhole requirement and need for high‑speed processing make 8011 the industry standard . Mingtai Aluminum produces 8011 foil for medicine foil applications with excellent sealing and moisture‑proof performance .
Food Containers and Lids — Yogurt cup seals, milk powder can lids, instant noodle lids, and food container lidding. 8011 provides the strength and formability needed for reliable sealing .
Industrial Applications — Cable shielding tape, air conditioning fins, and industrial stamping parts where strength and dimensional stability are required .
Choose 1235 Aluminum Foil When:
High‑End Food Packaging — Candy, chocolate, and snack wrappers requiring superior surface quality and gloss .
Flexible Packaging Lamination — As a lamination base for composite structures where the foil must bond cleanly with other materials .
Applications Requiring Deep Drawing — Complex shapes where maximum flexibility is needed .
Cost Considerations
8011 is generally more cost‑effective due to the lower raw material cost (less pure aluminum) and is often the popular mainstream option for its balance of performance and cost .
1235 may be slightly more expensive due to its higher purity (≥99.35% aluminum) . The premium is justified for applications where surface quality and purity are the primary requirements.
Conclusion: Which is Superior?
Neither grade is universally “superior” — the right choice depends on your specific application.
Choose 8011 if you need: Higher strength, better pinhole resistance, pharmaceutical‑grade barrier integrity, high‑speed processing compatibility, and cost‑effectiveness .
Choose 1235 if you prioritize: Maximum surface purity, excellent flexibility for deep drawing, high gloss appearance, and premium food contact quality .
For most flexible packaging applications — particularly pharmaceutical blister packaging, lidding, and general food packaging — 8011 offers the superior balance of performance and cost. For decorative, high‑purity, or deep‑draw applications, 1235 remains the preferred choice.
Contact Mingtai Aluminum today for free samples, technical data sheets, or a factory‑direct quotation for your flexible packaging project.
FAQ – 8011 vs 1235 Aluminum Foil
Q1: Which alloy is stronger, 8011 or 1235? A: 8011 is significantly stronger. It offers tensile strength of 70‑110 MPa compared to 45‑80 MPa for 1235‑O . The Fe and Si alloying elements in 8011 enhance its mechanical performance.
Q2: Which foil has better pinhole resistance?
A: 8011 has superior pinhole resistance due to its higher strength and refined microstructure. This makes it the preferred choice for pharmaceutical blister packaging where barrier integrity is critical .
Q3: Which alloy is more flexible and easier to form?
A: 1235 is softer and more flexible, making it ideal for deep‑draw applications like complex yogurt cup seals or jelly lids . However, 8011 still offers good ductility with the added benefit of higher strength.
Q4: Can both alloys be used for pharmaceutical packaging?
A: Yes, but 8011 is the preferred choice for pharmaceutical PTP blister packaging due to its superior pinhole resistance and strength .
Q5: Which is more cost‑effective?
A: 8011 is generally more cost‑effective due to lower raw material costs. It is often the mainstream choice for its balance of performance and cost .
Q6: What temper is used for flexible packaging foil?
A: Both 8011 and 1235 are commonly supplied in O temper (fully annealed, soft) for packaging applications . H18 temper (hard) is used for some industrial applications.
Q7: What certifications does Mingtai hold for packaging foil?
A: Mingtai‘s packaging foils meet food‑grade and pharmaceutical‑grade safety standards. The company is IATF 16949, ISO 9001, and ISO 14001 certified.
Q8: Can Mingtai supply custom thicknesses and widths?
A: Yes. Mingtai offers custom thicknesses and widths to meet specific packaging requirements. 8011 and 1235 foil are available in thicknesses from 0.005 mm to 0.2 mm and widths up to 1,600 mm .
Mingtai Aluminum – Packaging Foil Division
Phone: +86-17760728273
Email: sales@mingtai-al.com
Website: www.mingtaialuminum.com
Factory Address: Gongyi City Industrial Agglomeration Area, Henan, China
