Aluminium foil (HSN 7607), which comes under the broader segment of aluminium flat and rolled products, acts as an obstacle and prevents air leakage and insulates ducts, preventing consistent temperatures and minimising energy loss. It is also commonly used to wrap air conditioning coils, improving their thermal efficiency and extending their operational lifespan.
Source: Chalco
According to global market trends, the development of air conditioner heat exchangers is progressing toward ultra-thin profiles and higher strength. While the sheet thickness in the 1980s ranged between 0.15–0.2 mm, modern designs have reduced this to just 0.09–0.15 mm. However, to reinforce durability, minimise energy consumption, improve airflow, and optimise cooling performance, a variety of functional coatings have been introduced. These include anti-corrosion coatings, hydrophilic and hydrophobic surfaces, mould-resistant treatments, and self-lubricating finishes, each designed to extend the service life and efficiency of the heat exchangers.
The global aluminium foil market for air-conditioning applications is projected to expand, as per consumer product research driven by rising global demand for efficient cooling solutions, advancements in coil manufacturing, and regulatory pressure to adopt eco-friendly refrigerants such as R‑32*.
Many major air conditioner manufacturers (like Daikin, Mitsubishi Electric, Panasonic) have adopted R‑32 in their residential and commercial AC units to comply with global climate agreements like the Kigali Amendment to the Montreal Protocol.
R‑32's adoption has also affected aluminium foil demand in heat exchangers, as systems are being redesigned to accommodate its thermodynamic properties—often requiring more compact, high-efficiency coils using thinner aluminium fins.
Regionally, Asia‑Pacific dominates this market, fuelled by rapid urbanisation, industrial and residential AC installations in countries like China and India. North America and Europe are also significant players, propelled by stringent energy efficiency regulations, although their growth rates are more modest.
Top 10 AC exporting countries (by value, USD$)
On the supply side, manufacturers are investing heavily in R&D—in areas such as hydrophilic coatings, precision rolling, and alloy improvements—to deliver thinner yet durable foils optimised for energy efficiency and long-term performance. However, they face headwinds like volatile aluminium prices and intense market competition.
Aluminium foil in air conditioners is more than just a thermal conductor—it's becoming a focal point of innovation as manufacturers respond to stricter energy efficiency standards and environmental regulations. The drive to reduce refrigerant load and improve heat transfer efficiency has led to the development of microchannel heat exchangers, where thinner and more structurally precise aluminium foils are essential.
The industry faces mounting pressure to transition to recyclable or low-carbon aluminium sources to align with global decarbonisation goals.
Presently, aluminium foil in HVAC systems is contemplated as more than just a valuable product; as it is a high-value element, with its sourcing, alloying, and surface treatment now deeply unified with the sustainability and performance metrics that delineate the next-generation air conditioning technologies.
As air conditioning systems tend to become more energy efficient, and meet the demands of lowering energy consumption, environmental compliance, and compact design, aluminium foil gains momentum as a key element of innovation rather than a mere component, as per competitive analysis market research. Aluminium foil's role has expanded beyond thermal conductivity to include structural integrity, corrosion resistance, and sustainability.
The shift toward ultra-thin, high-performance foils, coupled with the growing emphasis on recyclable and low-carbon aluminium, reflects a broader change in HVAC manufacturing—from conventional engineering to material-driven optimisation.
When we look into the future, the advancement of aluminium foil technology will influence the definition of the next generation of climate control systems, where performance and sustainability are not trade-offs but shared imperatives.
*Note: R‑32 (difluoromethane) is a next-generation refrigerant used in air conditioning systems. It is part of the hydrofluorocarbon (HFC) family but has a much lower global warming potential (GWP) compared to older refrigerants like R‑22 or R‑410A.
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