Industrial Aluminum Foil

Industrial aluminum foil (IAF) provides a versatile solution useful for a variety of applications spanning a myriad of industries.  Though similar to traditional aluminum foil, IAF often includes the addition of other metals like magnesium, manganese, copper, nickel, silicon, or zinc, creating aluminum alloys with properties designed to meet specific industrial needs.
To establish additional distinctions and provide a better understanding of the importance of this material to industries, this page will explore the manufacturing process, beneficial properties, and relevant applications for IAF products.


IAF is produced by rolling aluminum slabs cast from molten aluminum, followed by rerolling on sheet and foiling mills until it reaches the desired thickness.  A slightly more cost-effective method of IAF fabrication includes continuous casting and cold rolling.  Finished sheets of industrial aluminum foil are available in continuous rolls, folded sheets, and more.  Most foil sheet thicknesses are below 0.008 inches.

IAF offers a range of beneficial properties that make it useful within a variety of applications within aerospace, industrial, chemical, food and beverage, and many other industries.  Some of these benefits include:

  • Flexibility
  • Low permeability
  • EMI/RFI shielding capabilities
  • Ability to withstand high temperatures
  • Low production cost


Sun Process Converting is a leading supplier of industrial aluminum foil.  Our IAF products come with a variety of adhesive options like high-performance solvent, emulsion, and silicone-based adhesives (rubber, acrylic, and heat activated formulas), as well as various high-performance release liners.  Our line of IAF products include:

  • Pressure Sensitive Dead Soft Aluminum
  • Flame-Retardant Industrial Aluminum Foil
  • PVC Heat Seal Aluminum Foil
  • High-Temperature Silicone Adhesive Aluminum Foil


Developed for EMI/RFI shielding, our Pressure Sensitive Dead Soft Aluminum products are made from zero temper foil with a pressure sensitive adhesive coating.

Features of this product include:

  • High dimensional stability
  • Excellent moisture/water resistance
  • Temperature range: -65°F to 300°F (-54°C to 149°C)
  • Printing options: Flexographic, offset, letterpress, and screen printing 


We use 2 mil and 5 mil Dead Soft Aluminum Foil laminated with flame-retardant polypropylene to provide EMI/RFI shielding for products and components that must operate in flammable environments.  This foil allows for part number/code embossing during die cutting, making it a viable option for product identification and coding.

Features of our flame-retardant industrial foil include:

  • High dimensional stability
  • Excellent moisture/water resistance
  • Temperature range: -40°F to 250°F (-40°C to 121°C)


Designed for use with wire/cable harnesses and heat element applications, PVC Heat Seal Aluminum Foil includes pressure sensitive adhesive coating and PVC heat sealant.  This provides a viable solution for plasticized products in environments with elevated temperatures.

Features of this product include:

  • High dimensional stability
  • Excellent moisture/water resistance
  • Temperature range: -65°F to 300°F (-54°C to 149°C)


Designed for high-temperature applications, this product includes Dead Soft Aluminum Foil backing with pressure sensitive silicone adhesive and clear, easy-release film liner.  Common applications of this product include hot air duct insulation adhesive, sealing automotive airbag inflators, moisture barriers around doors and windows to prevent fogging, and more.

Features of this product include:

  • High dimensional stability
  • Excellent moisture/water resistance
  • Temperature range: -65°F to 600°F (-54°C to 316°C)
High-Temperature Silicone Adhesive Aluminum Foil


Some of the most common industrial applications using industrial aluminum foil include:

  • Heating Elements. Flexible foil heaters provide a dependable and immediate heat transfer. They allow for even heat distribution and are ideal for low moisture applications that require a reliable, long lasting heat solution.  The aluminum foil helps produce a more efficient heat transfer and can be customized for a variety of applications. 
  • Insulation.  IAF provides an insulating layer for pipe and duct insulation or for building insulation.  The foil acts as a top layer for insulating materials like stone wool, foam panels, and lamellar mats due to its capacity to reflect approximately 96% of radiant heat. 
  • Vapor/moisture barriers. Low permeability properties make IAF a viable barrier against moisture and vapors in saunas or on basement walls.  Perforated varieties of foil used for roof insulation circulate air to help prevent condensation. 
  • Packaging. Low permeability, low toxicity, and highly hygienic properties make IAF a viable solution for packaging foods, chemicals, beauty products, and pharmaceuticals, among others.  IAF packaging may range from simple foil wraps to more complex solutions such as blister packs.  The significant protection properties of foil also facilitate safe storage and transportation of products. 
  • EMI/RFI shielding. Often used within the insulation of power cables, IAF helps to mitigate electromagnetic interference to surrounding electronic devices. 
  • Aluminum tapes. Aluminum tape is created by applying an adhesive to one side of the foil.  This tape is commonly used in applications with extreme cold or extreme heat because it will not lose durability under exposure to these conditions.  Electrical engineers also use aluminum tapes to block electromagnetic interference.  Construction workers also rely on aluminum tape for a variety of purposes. 


Industrial aluminum foil’s excellent insulating properties, vapor/water barrier capabilities, EMI/RFI shielding, and hygienic qualities have made a significant impact on a wide range of industries and applications.  Sun Process Converting is a provider of industrial aluminum foil products that meet a variety of industrial needs.

We offer an extensive portfolio of products and capabilities ranging far beyond IAF products to custom design services and custom converting.  Our 200,000-square foot facility is ISO 9001:2015-certified and recognized under the Underwriters Laboratory (UL) component program.

Contact us for more information about our industrial aluminum foil solutions or any of our other products and services.


  • Pressure Sensitive Dead Soft Aluminum (PDF)
  • Industrial Aluminum Foil Flame Retardant (PDF)
  • PVC Heat Seal Aluminum Foil (PDF)
  • High-Temperature Silicone Adhesive Aluminum Foil (PDF)