Foil Plain and Converted Aluminium Foil 077_MappeFoil2008_215x305.indd 1 09.04.2008 13:55:16 Uhr Hydro – an important catalyst in aluminium packaging development P rotection of contents, zero impact on taste, ease of formability for design purposes – only a few of the key requisites packaging materials have to meet, whether for food or pharmaceutical applications. We satisfy all these requirements with our precision aluminium foil products. Create value through innovative and efficient solutions Hydro is a Fortune Global 500 supplier of aluminium and aluminium products. Based in Norway, the company employs 22,000 people in more than 30 countries and has activities on all continents. Rooted in a century of experience in renewable energy production, technology development and progressive partnerships, Hydro is committed to strengthening the viability of the customers and communities we serve. Your first choice partner Hydro, through its Rolled Products Business Sector, is a worldwide leader in aluminium rolled products. With more than 85 years’ experience in aluminium rolling, our success is built on a strong network of European rolling mills, including a 50-per-cent share in the world’s largest hot 077_MappeFoil2008_215x305.indd 2 and cold rolling mill – Aluminium Norf in Germany. Dedicated supplier of high-quality foil for demanding packaging applications Through our Foil Business Unit, we produce high-quality aluminium foil for the packaging of food and pharmaceuticals as well as for technical applications. We specialise in thin-gauge foil – a key differentiation from our competitors. As one of the world’s leading producers, we supply foil as thin as 6.0 µm. Aluminium, with its unique barrier properties, has become an integral part of most packaging products today. We apply our extensive know-how to provide quality solutions and offer a full range of consulting and technical support services to help our customers define their specific packaging requirements and optimise their products. Our aluminium packaging solutions combine superior product quality with creativity, cost effectiveness and ecological soundness. Complete service With sales offices worldwide and rolling facilities in Germany, Italy and Spain as well as in Asia, we can offer our customers a complete service package – we are there exactly where you need us, when you need us! Since we speak the same language as our customers and understand their cultural background, we can tailor our technical and consulting services to fit their individual needs using a wide variety of production techniques. World-class technology With our state-of-the-art production facilities, we are prepared for the future requirements of the packaging industry. Our highly versatile, top-quality hot rolling processes are complemented by our extremely flexible, class-leading continuous strip casting process. Innovation Our Research and Development organisation is central to our work of continuously improving the properties of our products to ensure complete customer satisfaction, for example, increasing yield while safeguarding the same protective effects, enhancing adhesion properties or improving unwinding behaviour. Our R&D results contribute to best practice processing at optimum cost, for best quality products. Flexibility Smaller company units play an important role in providing us with key strategic advantages: they give greater flexibility in production, enabling us to manufacture not only different batch sizes but also a wide variety of foil products. This flexibility helps us satisfy our customers’ requirements for reliability and on-time delivery with the shortest possible lead times. Getting closer: our customer services Comprehensive technical and commercial services round off our customer service programme. Other offerings, such as an internet-based customer portal underline this partnership approach. 09.04.2008 13:55:23 Uhr Contact: Hydro Aluminium Foil Business Unit Tel: +49 2181 66-1638 Fax: +49 2181 66-1828 e-mail: info.foil@hydro.com www.hydro.com Plain and converted aluminium foil for flexible tobacco packaging T obacco products are consumed widely throughout the world. Like other sensitive goods, they require packaging which brings them to the customer in optimum condition. Aluminium foil has been the barrier material of choice for cigarette packaging for almost fifty years. It not only retains the characteristic aroma peculiar to each blend and brand but also gives the packaging a distinctive appearance and quality appeal. Added to this, an aluminium foil / paper laminate provides certain characteristics, such as deadfold and embossability, which other bundling materials cannot offer. Tobacco benefits from aluminium foil’s unequalled barrier properties in the same way as other sensitive natural products. The foil maintains an effective barrier against moisture and protects the tobacco from deterioration, aroma transmission and bacteria by sustaining a micro-climate in the package. With its non-returning dead-fold characteristic, aluminium can be formed to the desired shape with no “spring back” and provides the web strength and dependability essential to high-speed packing lines, where downtime is costly. Being highly malleable, aluminium foil makes high-quality embossing particularly effective. Despite changes in temperature and humidity, aluminium foil remains in its embossed pattern to cushion the cigarettes against impact and also heighten brand identity among consumers by conveying a sense of quality and distinctiveness. Hydro has accumulated considerable expertise and know-how in coating techniques and aluminium foil / paper laminates. Supported by a dedicated paper laboratory, we produce our own lacquers and specific laminate combinations to satisfy our customers’ exacting requirements. With sustainability and the environment high on the issue agenda, aluminium foil in cigarette packaging applications has a very positive environmental profile – it saves weight, cuts transport costs and prevents product spoilage. Advanced separation techniques allow aluminium foil to be recovered from post-consumer waste streams and recycled at a fraction of the original energy cost. Hydro’s worldwide logistics network facilitates product shipments from its four plants in Europe and Asia to customers around the globe. Product range: Please contact our Technical Customer Service for more detailed information Alloy EN / AA 1050, 1145, 1235 1200 8079 8111 077_EB_Cigarette_A4.indd 1 Temper O O O O Gauge [µm] 6 – 12 6 – 12 6 – 12 6 – 12 Width [mm] max. 1620 max. 2020 max. 2020 max. 1620 Surface plain or converted foil with bright / matt surface plain or converted foil with bright / matt surface plain or converted foil with bright / matt surface plain or converted foil with bright / matt surface 09.04.2008 16:53:58 Uhr Contact: Hydro Aluminium Foil Business Unit Tel: +49 2181 66-1638 Fax: +49 2181 66-1828 e-mail: info.foil@hydro.com www.hydro.com Real-time information 24/7 provides even more service: Hydro Customer Portal H ydro has extended its online service to give you, the customer, additional support in your daily tasks. This means a more comprehensive service and a quicker exchange of information – 24 hours a day, 7 days a week. The highest standards of data security ensure the basis for close, confidential cooperation. The following areas are available to you: 1. Orders & deliveries In this area, you have online access to the following information: • An overview of your orders, including the option to print out or store your order confirmation as a PDF file • A freight overview, showing the depart- 077_EB_Cust_Portal_A4.indd 1 ure date and, for sea transport, even the name of the vessel, the container number and the estimated times of departure and arrival. Invoices and packing lists can also be downloaded and printed out. • A stock list of the items produced against your order and ready for dispatch • A statement of account, including credits and debits 2. Technical support In this area, you can find information on: • Research and development facilities (sites, main areas of focus, contacts, etc.) • Frequently asked questions • Your particular Hydro contact and the option to share minutes of meetings • Technical specifications, data sheets and other key facts • Hydro’s Reel Calculator – a tool for calculating reel weights 4. Other In this area, you can find market information and news about Hydro. You can also download the plant certificates and “How to find us” of the respective plants. The Hydro Customer Portal supports and displays information from the company’s rolling mills. If you are interested in finding out more about this online tool, please contact your sales responsible at Hydro. 3. Commercial services This area gives you the opportunity to review: • Historical market prices 09.04.2008 13:45:46 Uhr Contact: Hydro Aluminium Foil Business Unit Tel: +49 2181 66-1638 Fax: +49 2181 66-1828 e-mail: info.foil@hydro.com www.hydro.com Plain and converted aluminium foil for flexible food packaging A luminium foil, whether unsupported or laminated to paper and films, is now an almost indispensable material for flexible packaging in the food industry. Every consumer is familiar with household foil, but foil is also widely used in sachets and pouches, dairy lids, bottleneck foil, capsules, labels, seals and a multitude of other applications. Aluminium foil comes in different gauges, typically ranging in thickness from 0.006 to 0.060 mm. Foil is not only cost-effective but also provides complete food protection. lt is unrivalled as a barrier layer, totally excluding light, gases, oil and fat, volatile compounds and water vapour. Aluminium foil is temperature resistant, thermally stable and an extremely good conductor of heat. It is also strong, durable and safe for use in contact with all foodstuffs. Foil as a packaging material has two other great advantages – its decorative potential and highresolution printability when used with such modern techniques as flexographic, gravure and offset litho printing. The bright or matt surface of aluminium foil provides designers with almost unlimited possibilities to give packaging a distinctive visual appearance for easy brand recognition. The unique “dead-fold” character of aluminium foil makes it the ideal material for close-wrapped chocolate and other types of confectionery; whether in plain or decorative embossed surface designs, alufoil is readily formed to fit the most complicated shapes. lated a vast amount of expertise in coating and converting and manufacture our own lacquers to meet our customers’ specific foil applications. In the face of growing environmental concerns, aluminium foil has a very positive environmental profile – it saves weight, cuts transport and storage costs and greatly reduces the spoilage of sensitive filled goods. Advanced separation techniques allow the aluminium foil in household waste to be recovered and recycled at a fraction of the original energy cost. Hydro’s worldwide logistics network facilitates product shipments from its four plants in Europe and Asia to customers in every corner of the globe. Aluminium foil can be laminated and coated easily. At Hydro, we have accumu- Product range: Please contact our Technical Customer Service for more detailed information Alloy EN / AA 1050, 1145, 1235 1200 8011, 8111, 8006, 8014 8079, 8021B Temper* O or H19 O or H19 O O Gauge* [µm] 6 – 60 6 – 60 6 – 60 6 – 60 Width [mm] max. 1620 max. 2020 max. 1620 max. 2020 Surface* plain or converted foil with bright / matt surface plain or converted foil with bright / matt surface plain or converted foil with bright / matt surface plain or converted foil with bright / matt surface *other gauges, temper or surface conditions on request 077_EB_Flexible_A4.indd 1 09.04.2008 16:54:43 Uhr Cold rolling in several steps (1) Intermediate annealing (2) Foil rolling in several steps (3) Foil doubling (4) Final foil rolling down to 0.006 mm (5) Slitting (6) Final annealing (7) Inspection and testing (8) Production process – foil rolling Process Following hot rolling or continuous strip casting, the next production step is cold rolling (1). After several cold rolling passes, however, the metal becomes so brittle that an intermediate heat treatment in the form of annealing (2) is required to soften the material. Thin-gauge foil is produced on dedicated foil mills (3), where a thickness reduction of approx. 50% is obtained with each pass. Before the final finishing pass, two layers of foil are rolled together or “doubled” (4). In the doubling machine, a spray system injects a very thin film of rolling oil between the two foil layers. The oil acts as a separating medium or release agent to prevent cold-welding between the two metallic surfaces during rolling. “Doubling” is normal practice when making foil with a thickness of 60 microns or less. The doubled foil is then rolled to its final gauge (5). This operation leaves the foil with its characteristic “one side bright – one side matt” appearance. After rolling, a “separation” step (6) takes place, where the doubled foil is simultaneously separated into single layers and slit to the requested width and length according to customers’ specifications. Finally, the material’s surface and runnability characteristics are controlled and tested on Hydro Aluminium’s dedicated inspection lines (8). The testing of all final products is absolutely essential to guarantee superior quality and forms an integral part of our aluminium foil production philosophy. Customised packaging protects our foil and ensures safe and easy handling as well as transportation and storage worldwide. To obtain “soft” foil, the material has to be annealed at high temperature for several days (7). The time and temperature are carefully set to allow the metallic grain structure to recrystallise and, at the same time, remove the rolling oil from the surface of the aluminium foil by evaporation. Contact: Hydro Aluminium Foil Business Unit Tel: +49 2181 66-1638 Fax: +49 2181 66-1828 e-mail: info.foil@hydro.com www.hydro.com 077_EB_Foil_Rolling_A4.indd 1 07.04.2008 15:34:59 Uhr Melting (1) Holding / Casting (2) Filtering (3) Sheet ingot casting (4) Scalping / Sawing (5) Preheating rolling ingots (6) Hot rolling (7) Strip coiling (8) Production process – sheet ingot casting and hot rolling Process Aluminium remelt ingots, typically with an aluminium content of 99.7%, are melted down in furnaces (1) at temperatures of between 800 and 900°C, blended together with alloying elements to achieve the desired chemical composition. The molten metal (2) – from remelting or from the electrolysis process – is conducted by a system of launders via a filter (3) to water-cooled moulds. The metal is filtered to remove any impurities from the melt and ensure good subsequent transformation behaviour and foil quality. In sheet ingot casting (4), water is used to directly chill the melt as itenters the vertical mould, causing the molten aluminium to solidify into a large rectangular ingot as the casting table is lowered continuously. Sheet ingots can reach a length of up to 8 – 9 m, with a width of 2,200 mm and a thickness of 600 mm. They can weigh up to 30 tonnes. After casting, the ingots are scalped (5), i.e. the casting skin is removed from the surface by machining, and the two ends sawn off. All process scrap is returned to the melting furnaces in a closed loop for immediate recycling. The next step is preheating (6). The ingots are preheated to about 500 – 600°C in push-through conveyor furnaces or in soaking pits and are held at this temperature for several hours. The preheating of ingots serves two purposes: firstly, to trigger metallurgical processes in order to obtain a homogeneous grain structure and, secondly, to facilitate subsequent rolling by reducing the metal’s mechanical resistance to fabrication. During hot rolling (7), the ingot is reduced in thickness from its initial 600 mm down to 2 mm by passing it several times forwards and backwards through a rolling mill. On completion of the hot rolling process, the strip is coiled for the first time (8). Advantages The hot rolling process is suitable for all types of alloys. Since the metal undergoes a high degree of mechanical working during rolling, a particularly homogeneous microstructure is achieved. The hot rolling process meets all the requirements of a streak-free, decorative and wear-resistant surface to provide our customers worldwide with a brilliant solution. Contact: Hydro Aluminium Foil Business Unit Tel: +49 2181 66-1638 Fax: +49 2181 66-1828 e-mail: info.foil@hydro.com www.hydro.com 077_EB_Hot Rolling_A4.indd 1 07.04.2008 15:35:45 Uhr Contact: Hydro Aluminium Foil Business Unit Tel: +49 2181 66-1638 Fax: +49 2181 66-1828 e-mail: info.foil@hydro.com www.hydro.com Plain aluminium foil for liquid packaging applications A luminium foil in packaging helps keep foodstuffs fresh for months without refrigeration. With its outstanding barrier properties and contributions to the sealing process, aluminium foil guarantees the excellent material and filling performance of aseptic and retortable packaging for milk, juices and soups. It prevents the contents from losing nutritional value, vitamins or aroma and gives total protection against light, moisture, oxygen, foreign matter contamination and damage. 0.006 mm and widths of up to 2020 mm. With our devotion to quality, reliability and environmental performance, we are able to meet our customers’ specific requirements. Hydro is the world’s leading supplier of thin-gauge aluminium foil for liquid aseptic packaging, in thicknesses down to Sustainability and waste minimisation are major issues today. Foil-lined liquid cartons are light – requiring only 1.5 g of alumin- ium to package 1 litre of fluid – easy to transport and ensure full, long-life protection. Advanced separation techniques allow aluminium foil in domestic waste to be recovered and recycled at a fraction of the original energy cost. Our foil is tailored and tested, ready for further processing and converting on the customers’ own production equipment. We guarantee excellent unwinding properties and trouble-free runnability to provide maximum productivity. Hydro’s worldwide logistics network facilitates product shipments from its four plants in Europe and Asia to customers around the world. Product range: Please contact our Technical Customer Service for more detailed information Alloy EN / AA 1050 1200 8079 8111 077_EB_Liquid_A4.indd 1 Temper O O O O Gauge [µm] 6 – 12 6 – 12 6 – 12 6 – 12 Width [mm] max. 1620 max. 2020 max. 2020 max. 1620 Surface plain foil with bright / matt surface plain foil with bright / matt surface plain foil with bright / matt surface plain foil with bright / matt surface 09.04.2008 16:55:58 Uhr Contact: Hydro Aluminium Foil Business Unit Tel: +49 2181 66-1638 Fax: +49 2181 66-1828 e-mail: info.foil@hydro.com www.hydro.com Plain and converted aluminium foil for flexible pharmaceutical packaging A luminium foil has numerous proper ties which make it ideal for the safe, convenient and versatile packaging of pharmaceutical products, such as tablets, powders and liquids. The unrivalled barrier properties of aluminium foil totally exclude the penetration of moisture, oxygen, aromas and other gases, as well as microorganisms and light. Sensitive products are therefore kept in perfect condition for long periods. Hygiene is another key factor in pharmaceutical packaging. Aluminium foil is non-toxic and non-hazardous to health and does not harbour or promote bacteria. It can be supplied in a totally sterile condition. Aluminium foil is also suitable for the application of tamper-evident seals and anti-counterfeiting security, such as holograms. The ease of coating, laminating, slitting, forming, printing and embossing aluminium foil makes it an extremely versatile material for the packaging designer. In the medical and personal care markets, aluminium foil is mainly used in pushthrough blisters as a high-barrier performance, sealable and breakable membrane. In cold-formed blisters or strip packs (e.g. for suppositories), aluminium’s excellent formability allows the material to be given highly complex shapes without impairing its barrier integrity. Hydro supplies aluminium foil in thicknesses from 0.006 to 0.060 mm in hard and soft temper. Foil can be provided with a heat-seal lacquer or prime-coated for printing or high-adhesion performance. At Hydro, we have wide-ranging coating and converting expertise and manufacture our own lacquers to meet customers’ exacting technical and design specifications. With sustainability and the environment now major issues, aluminium foil in pharmaceutical packaging has a very positive environmental profile – it saves weight, reduces transport and handling costs and affords sensitive pack contents complete protection. Advanced separation techniques allow the aluminium foil in domestic waste to be recovered and recycled at a fraction of the original energy cost. Hydro’s worldwide logistics network facilitates product shipments from its four plants in Europe and Asia to customers in every corner of the globe. Product range: Please contact our Technical Customer Service for more detailed information Alloy EN / AA 1050, 1145, 1235 1200 8011, 8111, 8006, 8014 8079, 8021B Temper* O or H19 O or H19 O O Gauge* [µm] 6 – 60 6 – 60 6 – 60 6 – 60 Width [mm] max. 1620 max. 2020 max. 1620 max. 2020 Surface* plain or converted foil with bright / matt surface plain or converted foil with bright / matt surface plain or converted foil with bright / matt surface plain or converted foil with bright / matt surface *other gauges, temper or surface conditions on request 077_EB_Pharma_A4.indd 1 09.04.2008 16:58:03 Uhr Our plants Grevenbroich Plant / Germany Hydro’s foil rolling plant in Grevenbroich is one of the biggest suppliers of rolled aluminium products worldwide. Commissioned in 1922, the plant has undergone a series of expansions and upgrades to keep its production facilities at the very forefront. We have been successfully manufacturing high-precision foil at this location for more than 85 years. With a workforce of around 1,900 employees, the plant has an annual capacity of 421,000 tonnes and produces sheet and strip in addition to foil for a wide range of applications and markets. Hydro Aluminium Slim S.p.A. / Italy Hydro Aluminium Slim, located 50 km south of Rome, was established in 1964. 077_EB_Plants-Offices_A4.indd 1 With a workforce of 570 employees, the plant currently has a capacity of 86,000 tonnes per year, producing thin-gauge foil for various market segments and strip products for diverse technical applications. Major investment programmes in the casthouse, foil rolling and finishing mills and heat treatment furnaces have led to significant improvements in product quality and production volume. Hydro Aluminium Inasa S.A. / Spain Hydro Aluminium Inasa is located near Pamplona in the North of Spain. This rolling plant is specialised in the production of thin-gauge foil and strip products primarily based on continuous strip casting. With 250 employees, Inasa produces 24,000 tonnes every year. Hydro Aluminium Malaysia Sdn Bhd / Malaysia Hydro Aluminium Malaysia, located in Pasir Gudang, started production in 1986. With annual output totalling 18,000 tonnes, it is one of the largest aluminium rolling mills in Asia, specialising in the production of high value-added packaging foil. Boasting state-of-the-art equipment, extensive technical know-how and marketing expertise, the company is a major player in the Asia-Pacific Region and constitutes a base for exporting Hydro Aluminium’s rolled products throughout the entire region. 08.04.2008 11:06:58 Uhr International sales offices Brazil Hydro Aluminium Rolled Products Latin America Rua Quintana, 887 – 3º andar – conj. 31 Brooklin Novo – São Paulo – SP Cep. 04569-011 Brazil Tel: +55 11 5105 0421 Fax: +55 11 5105 0420 Italy Hydro Aluminium Slim S.p.A. Piazzale dell’ Aluminio I-04012 Cisterna di Latina Italy Tel: +39 0696 8301 Fax: +39 0696 860352 Malaysia Hydro Aluminium Malaysia Sdn Bhd Lot 4, Jalan Pekeliling Pasir Gudang Industrial Estate 81700 Pasir Gudang, Johor Malaysia Tel: +60 7 25 41900 Fax: +60 7 25 24933 077_EB_Plants-Offices_A4.indd 2 Poland Hydro Aluminium Rolled Products Polska Sp.z.o.o. Ul Ceglielniana 37 PL - 30-404 Krakow Poland Tel: +48 12 664 224 Fax: +48 12 664 224 USA Hydro Aluminium USA, Inc. 666 Old Country Road , # 705 Garden City New York 11530 USA Tel: +1 516 222 1526 Fax: +1 516 222 2547 Spain Hydro Aluminium Inasa S.A. Aralar 9 E-31860 Irurtzun, Navarra Spain Tel: +34 94 860 8102 Fax: +34 94 860 8111 United Kingdom Hydro Aluminium UK Ltd. 4, Newton Court West Strand Pendeford Business Park Wolverhampton WV9 5HB United Kingdom Tel: +44 1902 396630 Fax: +44 1902 396640 08.04.2008 11:07:00 Uhr Melting (1) Holding / Casting (2) Filtering (3) Strip casting (4) Strip coiling (5) Production process – continuous strip casting Process Continuous casters produce coiled strip directly from molten aluminium in a single operation. Basically, the equipment consists of two furnaces (1) and (2), a filtering device (3), the strip caster itself (4) and a coiling stand (5). The molten aluminium is cast directly into 5 to 10 mm thick strip. By means of hydrostatic pressure, the molten aluminium is forced through a nozzle between two water-cooled casting rolls (4). The strip is subsequently coiled (5) when still hot (approx. 200°C). Production begins in the casthouse. Two furnaces (1) and (2) are necessary to guarantee a continuous uninterrupted feed of molten metal into the casting equipment. The preferred combination is a melting furnace along with a holding / casting furnace. The melt is cleaned in a filter (3) then transported to the continuous caster by means of a launder system. Advantages The continuous strip casting process facilitates the manufacture of a wide variety of end products, ranging from converted foil for packaging to thin strip for technical applications. by its rapidity and flexibility. The cast strip displays outstanding tensile strength and formability. Coil diameter and strip width can be adjusted to meet the specific needs of the customer at no great expense. Continuous casters can be operated for up to 20 – 25 days at a time without interruption, as long as the desired cast strip width remains the same. In addition to short throughput times, low energy consumption is the decisive factor in the economy efficiency of this process. The manufacturing process is characterised not only by its very high precision but also Contact: Hydro Aluminium Foil Business Unit Tel: +49 2181 66-1638 Fax: +49 2181 66-1828 e-mail: info.foil@hydro.com www.hydro.com 077_EB_Strip Casting_A4.indd 1 07.04.2008 15:40:33 Uhr 077_MappeFoil2008_215x305.indd 3 09.04.2008 13:55:40 Uhr Hydro is a Fortune Global 500 supplier of aluminium and aluminium products. Based in Norway, the company employs 22,000 people in more than 30 countries and has activities on all continents. Rooted in a century of experience in renewable energy production, technology development and progressive partnerships, Hydro is committed to strengthening the viability of the customers and communities we serve. Hydro Aluminium Rolled Products / Foil Business Unit Aluminiumstr. 1 41515 Grevenbroich Germany Tel: +49 2181 661638 Fax: +49 2181 661828 E-mail: info.foil@hydro.com www.hydro.com 1,500/04/2008 © Hydro 2008 077_MappeFoil2008_215x305.indd 4 09.04.2008 13:55:50 Uhr