Market Insight: Aluminum Foil Maker

Market Analysis: Transformer Strip/Foil (Aluminum/Copper)

The global demand for transformer strip and foil—fabricated from high-purity aluminum and copper—continues to expand in parallel with the growth of electrical infrastructure, renewable energy integration, and industrial automation. As a core component in power and distribution transformers, these conductive materials serve as windings that enable efficient electromagnetic energy transfer. Aluminum foil, in particular, has gained substantial market traction due to its favorable combination of electrical conductivity, low density, and cost-effectiveness compared to copper. This has positioned aluminum foil makers as critical suppliers within the transformer manufacturing supply chain.

Industrial demand for aluminum transformer foil is driven primarily by the power transmission and distribution (T&D) sector, where medium and large power transformers require continuous, high-performance winding materials. The shift toward energy-efficient transformers, mandated by regulatory standards in regions such as the EU, North America, and China, has further intensified the need for precision-engineered foil with consistent electrical and mechanical properties. Additionally, the proliferation of renewable energy systems—especially solar and wind installations—requires step-up and grid-connection transformers that rely heavily on high-quality aluminum strip and foil.

Aluminum foil used in transformer windings must meet strict technical specifications. Typical thickness ranges from 0.20 mm to 6.0 mm, with tight tolerances (±0.01 mm or better) to ensure uniform winding tension and thermal management. The material must exhibit high electrical conductivity (minimum 61% IACS for aluminum), excellent surface cleanliness, and minimal edge defects to prevent dielectric breakdown. Moreover, the foil must possess sufficient ductility and tensile strength to endure the coiling, bending, and clamping processes during transformer assembly without cracking or delamination.

Quality is not merely a performance differentiator—it is a reliability imperative. Substandard foil can lead to localized hot spots, increased eddy current losses, and premature transformer failure. In high-voltage applications, microscopic surface irregularities or non-uniform oxide layers can initiate partial discharges, accelerating insulation degradation. Transformer manufacturers therefore prioritize suppliers capable of delivering batch-to-batch consistency, traceable material certifications, and adherence to international standards such as IEC 60464, ASTM B419, and GB/T 3190.

At Luoyang Xinzhaohe Aluminum Co., Ltd., with over two decades of specialized production experience, we engineer transformer strip and foil to meet these exacting demands. Our manufacturing process integrates precision rolling, controlled annealing, and in-line surface inspection to ensure optimal microstructure and dimensional accuracy. We supply both aluminum and copper-based products tailored to customer specifications, supporting global transformer OEMs in achieving higher efficiency, longer service life, and compliance with evolving energy regulations.

As the energy landscape evolves, the role of the aluminum foil maker becomes increasingly strategic. Only through rigorous quality control and materials expertise can suppliers meet the technical demands of modern transformer design and support the reliability of next-generation power systems.

Technical Specs: Aluminum Foil Maker

Technical Specifications for Transformer Foil Production
Luoyang Xinzhaohe Aluminum CO.,Ltd leverages 20+ years of metallurgical expertise to deliver transformer strip and foil meeting the most stringent electrical industry requirements. Precision slitting, edge quality, and conductivity are non-negotiable parameters for reliable transformer performance, directly impacting core loss, thermal management, and winding integrity. Our manufacturing process employs advanced tension control systems, laser-guided slitting, and in-line metrology to ensure conformance to the specifications detailed below.

Precision slitting at ±0.002 mm tolerance is achieved through our proprietary dual-axis tension control system and hardened tungsten carbide rotary shear blades. This eliminates micro-tearing during high-speed slitting (up to 1,200 m/min), which is critical for maintaining dimensional stability under transformer winding tension. Edge burr formation is mitigated via precision blade clearance calibration (0.5% of material thickness) and in-line electrochemical deburring, verified through scanning electron microscopy (SEM) to ensure burr heights remain below 1.5 μm. Exceeding this threshold risks insulation breakdown in high-voltage applications.

Conductivity of 61.0 %IACS minimum for 1070 aluminum alloy is maintained through strict melt chemistry control (Fe+Si ≤ 0.15%, Ti ≤ 0.03%) and optimized homogenization annealing. This exceeds IEC 60146-1-1 requirements for low-loss transformer windings, directly reducing eddy current losses by 8–12% compared to standard commercial purity foils. Surface roughness is controlled via precision 4-high cold rolling with mirror-finish work rolls (Ra ≤ 0.02 μm), ensuring uniform varnish penetration and adhesion during coil impregnation.

All batches undergo 100% inline width monitoring via laser micrometers and offline verification per ISO 2178. Traceability is maintained through our ERP-integrated quality management system, documenting melt chemistry, process parameters, and final test results for every coil. This technical rigor ensures our aluminum transformer foil consistently meets the operational demands of high-efficiency distribution and power transformers, where even micron-level deviations compromise system reliability. Partnering with Xinzhaohe guarantees adherence to these specifications through empirical validation and metallurgical process ownership.

Factory Tour: Manufacturing

Manufacturing Process for Transformer Strip and Foil at Luoyang Xinzhaohe Aluminum CO., Ltd

The production of high-performance aluminum and copper transformer strip and foil at Luoyang Xinzhaohe Aluminum CO., Ltd is a tightly controlled, multi-stage process designed to meet the rigorous demands of the electrical and power transmission industries. With over two decades of metallurgical expertise, our manufacturing workflow integrates precision engineering with advanced quality control to deliver materials exhibiting uniform thickness, superior surface integrity, and optimal electrical conductivity.

The process begins with cold rolling, where pre-annealed aluminum or copper ingots are reduced to precise foil gauges through a series of rolling stands under controlled temperature and tension conditions. Cold rolling is critical in achieving the desired mechanical properties and dimensional accuracy, particularly for applications requiring tight tolerances in thickness—often down to ±0.002 mm. Our state-of-the-art rolling mills utilize computerized thickness gauging systems (X-ray and laser-based) to ensure real-time monitoring and immediate correction of deviations. This stage also enhances the material’s grain structure, contributing to improved formability and thermal stability in end-use transformer windings.

Following cold rolling, the continuous strip undergoes precision slitting to achieve specified widths tailored to customer design requirements. Our slitting lines are equipped with high-precision circular knives and tension leveling systems that minimize edge waviness and maintain flatness across the entire coil. The slitting process supports narrow widths down to 5 mm with strict control over burr formation and dimensional consistency. Each slit coil is wound under controlled tension to prevent telescoping and ensure smooth unwinding during downstream processing.

Edge conditioning is the final critical step in the manufacturing sequence. The slit edges are processed through a proprietary edge rounding and deburring system to eliminate micro-cracks, sharp burrs, and surface defects that could lead to insulation damage or electrical arcing in transformer applications. This conditioning enhances the winding performance and dielectric reliability of the foil, particularly in high-voltage transformers where edge integrity directly impacts operational safety and longevity.

Throughout the production cycle, comprehensive quality control protocols are enforced. In-process inspections include surface defect scanning (using high-resolution CCD systems), thickness profiling, and tensile testing. Final inspection involves 100% eddy current testing for subsurface anomalies, in addition to visual and dimensional audits. All material batches are traceable via our integrated quality management system, complying with ISO 9001 standards and customer-specific technical specifications.

This disciplined approach to manufacturing ensures that every coil of transformer strip or foil produced at Luoyang Xinzhaohe meets the highest benchmarks for performance, reliability, and consistency in global power infrastructure applications.

Packaging & Logistics

Export Packaging Specifications for Transformer Strip and Foil

Luoyang Xinzhaohe Aluminum CO., Ltd implements rigorously engineered export packaging protocols to ensure the integrity of aluminum and copper transformer strip and foil during global maritime transit. With over two decades of metallurgical and supply chain expertise, our systems address the dual threats of physical damage and environmental degradation inherent in sea freight. Transformer-grade conductive materials demand absolute protection against moisture ingress, salt aerosol exposure, and mechanical shock, as even minor contamination or deformation compromises electrical performance and core lamination efficiency.

All shipments utilize ISPM15-certified wooden pallets constructed from kiln-dried, debarked hardwood. Pallet dimensions and load capacities are engineered to ISO 1 pallet standards, with structural reinforcement at stress points to prevent warping or collapse under dynamic cargo movement. Critical specifications include:

The core protective layer consists of multi-laminate moisture-proof film with a certified water vapor transmission rate (WVTR) of ≤0.5 g/m²/24hr at 38°C and 90% RH, per ASTM F1249. This film incorporates aluminum oxide barrier layers to block oxygen and salt particulates while maintaining electrostatic dissipation properties essential for coil handling. Each coil undergoes vacuum-sealing within the film to eliminate internal humidity pockets, followed by heat-shrink encapsulation that conforms precisely to the coil’s geometry without creasing. Desiccant packs (minimum 30% moisture absorption capacity by weight) are strategically positioned within the sealed envelope to capture residual moisture during extended voyages.

For sea freight security, palletized loads are secured using tension-controlled steel strapping (minimum 15 mm width, 15 kN break strength) applied at four vertical and six horizontal planes. Edge protectors distribute strap pressure to prevent coil deformation, while anti-slip pallet covers eliminate lateral shift during vessel motion. Container loading adheres to IMO CTU Code guidelines, with mandatory dunnage placement to isolate cargo from container walls and floor seams where condensation accumulates. All shipments include hygrometers to monitor internal humidity levels throughout transit, with real-time data accessible via IoT loggers upon client request.

This integrated approach mitigates risks across the maritime supply chain, from port humidity fluctuations to tropical monsoon exposure. Luoyang Xinzhaohe’s packaging compliance with IEC 60404-9 and ASTM B660 standards ensures transformer materials arrive with surface cleanliness levels <5 mg/m² and dimensional tolerances within ±0.005 mm—critical for high-efficiency core manufacturing. We subject all packaging configurations to simulated voyage testing, including 21-day salt spray and 50-cycle vibration trials, to validate performance against actual shipping conditions. Partnering with certified freight forwarders, we maintain full chain-of-custody documentation to guarantee packaging integrity from factory gate to destination facility.

Sourcing from Luoyang Xinzhaohe

Partner with Luoyang Xinzhaohe Aluminum CO., Ltd – Your Trusted Source for High-Performance Transformer Strip and Foil

With over two decades of specialized manufacturing experience, Luoyang Xinzhaohe Aluminum CO., Ltd stands as a leading industrial supplier of precision aluminum and copper transformer strip and foil. Strategically located in Luoyang, Henan Province—a recognized hub for non-ferrous metal production in China—our facility integrates advanced metallurgical engineering with rigorous quality assurance to deliver materials that meet the exacting demands of global power and electronics markets.

Our production infrastructure is built around continuous casting and rolling technology, enabling precise control over grain structure, mechanical properties, and dimensional tolerances. We operate fully automated rolling mills equipped with laser-based thickness monitoring systems, ensuring consistent foil gauge down to ±0.002 mm. This level of precision is critical for transformer applications where electrical efficiency, thermal management, and dielectric performance are directly influenced by material uniformity. Our aluminum foil products are available in alloys 1060, 1070, 1100, and 8011, supplied in tempers O, H14, H16, and H18, with thicknesses ranging from 0.01 mm to 3.0 mm and widths up to 1,600 mm. For copper transformer strip, we offer high-conductivity C11000 and C10200 in accordance with GB/T 5584 and IEC 60464 standards.

All materials undergo comprehensive in-house testing, including conductivity measurement (≥58 MS/m for Cu, ≥56 MS/m for Al), tensile strength evaluation, elongation analysis, and surface defect inspection via high-resolution optical scanning. Our quality management system is certified to ISO 9001:2015, and we maintain full traceability from raw material intake to finished coil shipment. This ensures compliance with international specifications for use in dry-type transformers, current transformers, and high-frequency switching power supplies.

We specialize in customized solutions, including slit-to-length cutting, edge conditioning, and anti-oxidation coating applications tailored to customer processing requirements. Our logistics network supports containerized FCL and LCL shipments with documentation compliant with CE, RoHS, and REACH regulations, enabling seamless integration into global supply chains.

As a vertically integrated manufacturer, we control every stage of production—from billet homogenization to final packaging—delivering cost efficiency without compromising technical performance. Our engineering team collaborates directly with clients to optimize material selection, reduce scrap rates, and support new product development.

For sourcing managers and technical procurement teams seeking a reliable, high-capacity supplier of transformer strip and foil, Luoyang Xinzhaohe offers proven capability, consistent quality, and responsive service. We invite you to strengthen your supply chain with a partner backed by 20 years of metallurgical expertise.

Contact us today to discuss your specifications and receive a technical datasheet and sample package.
Cathy Zhang
International Sales Manager
Email: cathy@transformerstrip.com