Pop-Up Aluminum Foil Sheet Weight Chart 2026

Pop-up aluminum foil sheet weight depends on sheet size and gauge, not the count printed on a dispenser. A box marked 500 sheets tells you the count, not how much aluminum is inside. A plain 9 x 10.75 inch sheet calculated at 15 microns contains about 2.53 g of aluminum, or 1.264 kg per 500 sheets. At 20 microns, the same size rises to 3.37 g per sheet and 1.685 kg per 500. The sheet count has not changed. The base-foil mass has.

This pop-up aluminum foil sheet weight chart turns five published foodservice sheet sizes into a common set of mass and yield figures. It covers grams per sheet, theoretical sheets per kilogram, and net aluminum for 200- and 500-sheet packs. All values describe plain base aluminum before dispenser boxes, shipping cartons, coatings or printing.

Jump to: weight chart | calculation | box-weight differences | embossing and stack height | receiving check | limits | specification line

Pop-Up Aluminum Foil Sheet Weight Chart

The table uses the exact metric conversion of each inch dimension. A value in the Sheets/kg column is a theoretical material yield, not a box count. The two net-kilogram columns include the aluminum sheets only.

7-, 8-, and 9-inch sheet widths

12- and 14-inch sheet widths

Source and method: Qixin Packaging calculation, version 2026-09-06. Dimensions are from Handi-Foil’s public foodservice range. The calculation applies nominal projected area, the listed micron scenario and 2.70 g/cm3 nominal density.

Download the 20-row CSV

Suggested citation: Qixin Packaging. Pop-Up Aluminum Foil Sheet Weight Chart 2026. Version 2026-09-06.

How Pop-Up Aluminum Foil Sheet Weight Is Calculated

For a rectangular sheet, the metal volume is its projected area multiplied by nominal thickness. Multiplying that volume by nominal density gives mass. With area in square metres and thickness in microns, the short form is:

mass per sheet (g) = width (m) x length (m) x thickness (microns) x 2.70

The 2.70 factor comes from using 2.70 g/cm3 as the nominal density. The Aluminum Association publishes nominal alloy densities for weight-per-area calculations and notes that composition changes the exact value. This chart therefore works as a planning reference. A purchase tolerance still belongs in the current product specification.

Worked example: 9 x 10.75 inches at 15 microns

NIST defines one inch as exactly 25.4 mm, so the projected dimensions are 228.60 x 273.05 mm. Their area is 0.062419 m2.

0.062419 x 15 x 2.70 = 2.528 g per sheet

Divide 1,000 by 2.528 to obtain about 395.6 theoretical sheets per kilogram. Multiply 2.528 g by 500 and divide by 1,000 to obtain 1.264 kg of base foil in a 500-sheet count.

One weight can describe two different sheets

The table contains a useful collision. A 9 x 10.75 inch sheet at 20 microns and a 12 x 10.75 inch sheet at 15 microns both calculate to about 3.37 g. The first is narrower and thicker. The second is wider and thinner. Their products of width and thickness are equal because the length is shared.

This is why a scale result by itself cannot identify both dimensions and gauge. The order record must preserve finished width, finished length and the thickness or basis-weight definition. A single mass value leaves more than one possible construction.

Why Equal Sheet Counts Produce Different Box Weights

When two 500-sheet boxes are compared, pop-up aluminum foil sheet weight is the missing variable. A 500-sheet declaration fixes one multiplier. It says nothing about the mass of each sheet. Width, length and micron determine the base-aluminum figure. The dispenser and shipping pack then add their own tare.

gross dispenser weight = sheet count x finished-sheet mean + dispenser and insert tare

Two boxes can also reach a similar gross weight by different routes. One may contain more, lighter sheets; another may contain fewer, heavier sheets; a third may use a heavier dispenser. To verify the sale unit, check count and clean-sheet mean separately before reconciling the gross box.

Embossing Changes The Stack Before It Changes The Math

The raised pattern on an embossed sheet creates air spaces between layers. It also changes the way the stack springs back after compression. A deeply embossed 500-sheet stack may need more box depth than a smoother stack made from the same nominal base gauge.

That extra height is apparent caliper, not newly created aluminum. The pattern can make a sheet feel fuller in the hand and can affect separation at the dispenser opening. It does not turn a 15 micron base foil into the same metal mass as an 18 micron base foil. Web draw, finished dimensions and process variation can still move the real result, so finished-sheet mean mass is the better reconciliation value.

Why a micrometer reading can mislead

A micrometer placed across emboss peaks reads the textured profile at that point. It may capture peak-to-valley geometry rather than the average metal thickness. ASTM E252 uses mass, known area and density when conventional point-contact readings are not accurate enough for thin foil. For an embossed finished product, the specification should say whether it controls base-foil micron, mass per unit area, finished-sheet mean mass, or more than one of these.

Bright side and dull side do not change base mass

The two surface appearances come from the rolling route. Turning one side upward does not alter the amount of aluminum in the sheet. A coating, lacquer, adhesive or printed layer is different because it adds another material. Use a finished-sheet target when those layers are part of the supplied product, and keep the plain-base calculation as the aluminum reference.

A Pop-Up Aluminum Foil Sheet Weight Check That Separates The Variables

Start with loose sheets, not the unopened dispenser. Count a group, weigh it without the box or insert, and divide the group mass by the actual count. A group reading is easier to interpret than one very light sheet because scale display rounding matters less.

For the 9 x 10.75 inch, 15 micron row, 20 calculated sheets contain 50.56 g of base aluminum. If 20 clean finished sheets weigh 51.2 g in a worked receiving example, their mean is 2.56 g. Multiplying by 500 gives 1.280 kg of finished-sheet mass. The gap between that figure and the unopened dispenser weight is packaging tare, subject to count and scale accuracy.

Keep the group mass, sheet count, scale division, finished dimensions, lot and date. A report that retains only the rounded 2.56 g average cannot be checked later.

Limits Of The Pop-Up Aluminum Foil Sheet Weight Chart

The chart estimates foil sheets per kilogram from projected area, micron and nominal density; it does not predict saleable yield after setup loss or rejected sheets. Width and length tolerances affect area. Density varies slightly with alloy composition. Printing and coatings add mass. Finished edges and interfolding can also shift the sheet dimensions measured in service. These are ordinary specification variables. They are the reason a calculated reference and an agreed acceptance value should not be treated as the same field.

Inch and metric labels

The exact conversion of 9 x 10.75 inches is 228.60 x 273.05 mm. A commercial label may shorten that to 22.9 x 27.3 cm. That rounding changes the calculated area by well under 0.2%, so it cannot explain a large weight difference. Use whichever unit system controls the drawing and avoid converting a rounded metric label back into a new inch value.

Write The Sheet And The Box On One Specification Line

A useful order description keeps the metal basis and the sale unit together. For example:

Interfolded aluminum foil sheet, 228.60 x 273.05 mm finished nominal size, 15 micron nominal plain base foil, embossed silver surface, 500 sheets per dispenser; calculated base-aluminum reference 2.528 g/sheet and 1.264 kg/500 sheets. Finished-sheet mass, dimensions, count tolerance, alloy/temper and dispenser tare to the approved order specification.

This line turns pop-up aluminum foil sheet weight from a loose estimate into a field that can be checked against the supplied lot. It also prevents the pack count from standing in for the sheet construction. For a coloured or printed sheet, add the coating or print system and control finished-sheet mass separately. For variable-length wrapping work, use the aluminum foil roll weight and length calculation instead of applying a fixed-sheet table.

Qixin supplies foodservice pop-up aluminum foil sheets and coloured pop-up foil sheets. Send the finished sheet size, base micron, surface, count and packing route through the Qixin contact page when you need a current product specification and quotation.

Pop-Up Aluminum Foil Sheet Weight Sources And Dataset Revision

• Handi-Foil: Interfolded Foil Sheets, foodservice dimensions and 200-500 sheet quantity range.
• Inteplast: Aluminum Foil Sheets, 9 and 12 x 10.75 inch formats and 200/500-count packing examples.
• Confoil: Foil Rolls & Sheets, rounded metric pop-up formats.
• NIST: SI Units – Length, exact 25.4 mm inch definition.
• The Aluminum Association: Teal Sheets December 2025, nominal density calculation context.
• ASTM E252-24, the mass, known-area and density relationship for foil thickness.

Revision: version 2026-09-06 contains 20 calculated rows. Future versions should retain the dimension source, micron scenario, nominal density and revision date so older citations remain interpretable.