Why Is 8011 Alloy the Preferred Material for PTP Aluminum Foil?

In the pharmaceutical packaging industry, PTP (Press Through Package) blister aluminum foil is one of the most widely used formats for tablets and capsules. As a critical material that directly affects drug safety, packaging efficiency, and patient experience, PTP foil places extremely stringent requirements on alloy selection.

Among various aluminum alloys, 8011 alloy, supported by decades of industrial application, stable comprehensive performance, and excellent process compatibility, has become the globally recognized first-choice material for pharmaceutical PTP aluminum foil.
As a long-term supplier of pharmaceutical packaging foil, we provide a systematic analysis of why 8011 alloy stands out across multiple dimensions.

Overview of 8011 Alloy

Pharmaceutical products-especially effervescent tablets and capsules-are extremely sensitive to moisture, oxygen, and light. Once oxidation or moisture ingress occurs, drug efficacy can rapidly degrade or even fail.

8011 belongs to the 8xxx series aluminum alloys, primarily alloyed with iron (Fe) and silicon (Si). Compared with pure aluminum (1xxx series), its crystal structure is more compact. Even at thicknesses as low as 20-30 microns, it delivers excellent moisture resistance, gas barrier performance, and light shielding, ensuring drug stability over shelf lives of 2-3 years.

In the H18 temper (full hard), 8011 achieves significantly higher yield strength than pure aluminum, allowing thinner gauges to meet stiffness and protection requirements, which is essential for high-speed blister packaging.

Core Chemical Composition of 8011 Alloy

Alloy	Fe	Si	Cu	Mn	Mg	Zn	Other	Al
8011	0.6 - 1.0 %	0.5 - 0.9 %	≤ 0.1 %	≤ 0.2 %	≤ 0.1 %	≤ 0.1 %	≤ 0.15 %	remainder

The precise Fe-Si ratio forms fine intermetallic compounds that significantly enhance strength and anti-wrinkling performance without sacrificing ductility.

Low impurity levels ensure exceptional material cleanliness, fundamentally eliminating pinhole defects, this is the physical foundation of high barrier performance.

8011 PTP Aluminum Foil Specifications

Alloy	8011
Temper	H18
Thickness	0.018 - 0.030 mm
Width	300 - 1200 mm
Length	C
Inner Diameter (ID)	76 mm / 152 mm
Supply Form	Jumbo rolls / Slitted rolls
Surface	One bright side / one matte side (standard for PTP)
MOQ	1-3 tons

	Property	Value
Physical Properties	Density	2.70 g/cm³
	Thermal Conductivity	160-180 W/m·K
	PTP Thickness Range	20-30 μm
	Oxygen Transmission Rate	≤ 0.5 cm³/(m²·24h·0.1MPa)
Mechanical Properties	Ultimate Tensile Strength	120-150 MPa
	Yield Strength	40-60 MPa
	Elongation at Break	≥ 15 %
Surface Properties	Surface Roughness	Ra ≤ 0.3 μm

Core Applications of 8011 PTP Aluminum Foil

1. Blister Packaging

Role: Lidding foil (push-through backing material)

Advantages:
Provides near-perfect barrier protection against moisture, oxygen, and light. Bonds easily with PVC, PVDC, PP, and PET blister films while maintaining controlled push-through performance for patient use. Soft temper foil ensures crack-free sealing during blister forming.

2. Laminated Pouches and Stand-Up Bags

Role: Intermediate barrier layer in composite structures

Advantages:
When laminated with PET, PE, or PP via dry or solvent-free lamination, aluminum foil provides ultra-high barrier performance for moisture- and oxygen-sensitive pharmaceuticals such as biologics, antibiotics, and ophthalmic solutions. It also enhances overall package strength and durability.

3. Sealing Foils and Bottle Liners

Role: Sealing material for pharmaceutical bottles, tubes, and containers

Advantages:
Ensures absolute sealing and tamper evidence prior to opening. Typically supplied in H18 temper for rigidity and coated with heat-seal lacquer for strong adhesion to container openings.

4. Medical Device and Diagnostic Packaging

Role: Sterilization pouches and light-shielding bags

Advantages:
Capable of withstanding steam sterilization, high-pressure processes, and ETO sterilization while maintaining package integrity and barrier performance throughout the product's shelf life.

PTP Aluminum Foil Manufacturing Process

Step 1: Melting and Casting

High-purity aluminum ingots are alloyed with Fe and Si according to the 8011 composition and refined in sealed furnaces. After degassing and filtration, the melt is cast into slabs approximately 6-8 mm thick.

Step 2: Cold Rolling and Intermediate Annealing

The slabs undergo multi-pass cold rolling. Rolling force, speed, and cooling are precisely controlled to achieve target mechanical properties. Intermediate annealing may be applied to adjust ductility.

Step 3: Foil Rolling

Using high-precision foil rolling mills, the material is reduced to final thickness (e.g., 0.025 mm). Thickness tolerance is strictly controlled within ±3% or tighter for pharmaceutical-grade foil.

Step 4: Annealing (If Required)

For O temper or specific hardness requirements, annealing is performed in protective atmosphere furnaces to relieve internal stress and ensure uniform properties.

Step 5: Surface Treatment and Coating

In cleanroom environments, functional coatings are applied:

Printing layers

Protective lacquers

Heat-seal coatings (critical for bonding with blister films)

Step 6: Slitting and Inspection

Foil is slit to customer-specified widths. Continuous online and offline inspections ensure compliance before clean packaging.

Core Advantages of 8011 Alloy in PTP Foil

High Strength and Structural Stability
Resists deformation and rupture during transport and stacking.
Excellent Formability
Stable performance in deep-drawing and complex forming applications.
Superior Barrier Performance
Effectively blocks moisture and oxygen when combined with functional coatings.
Lightweight and Cost Efficiency
Higher strength allows thinner gauges, balancing material cost and performance.
Excellent Surface Treatment Compatibility
Supports printing, coating, and surface finishing without compromising strength.
Non-Toxic, Odorless, and Sterile
Fully compliant with FDA, EU, and Chinese pharmaceutical packaging regulations.