Many aluminum foil converters are looking for reliable machinery to produce boxed embossed pop-up foil sheets. Standard slitter rewinder machines can only make foil rolls; they cannot handle embossing, folding, counting, and pop-up sheet production all in one. That is where our FDF 680mm aluminum foil pop-up sheet machine comes in, purpose-built for this exact product.
What product does this machine make?
This equipment manufactures Boxed Embossed Pull-out Tissue with Aluminum Foil Lining. The finished goods are interleaved pop-up foil sheets packed inside dispenser boxes, widely used for food service, barbecues, and baking packaging.
It works with single-layer aluminum foil, thickness from 0.009 to 0.025 mm with ±5% tolerance. The incoming jumbo roll uses a standard 3-inch (76 mm) core. Max roll diameter reaches Ø600 mm and maximum feeding width is 680 mm, compatible with most common foil raw materials available on the market.
Core working principle: Vacuum adsorption & hemming folding
Different from ordinary cutting machines, this unit forms foil sheets through vacuum adsorption and hemming technology. Equipped with a Roots vacuum pump system, it carries out perforation and straight knife cutting, followed immediately by V-fold cross folding for a smooth pop-up effect.
Embossing is done on steel polyurethane rollers to deliver sharp, clear patterns. Customers can swap embossing rollers for custom textures, great for private label branding. Full column automatic counting is built in. The whole workflow — jumbo roll loading, embossing, perforating, cutting, folding and sheet counting — completes on one single machine. No intermediate handling required.
Hardware setup & production capacity
The unwinding station uses a magnetic powder brake together with an air-expanding shaft for easy jumbo roll loading. A constant tension motor keeps foil stable during high-speed running, preventing stretching and wrinkling of thin-gauge aluminum foil.
The machine can run 2 columns simultaneously. It delivers 500 sheets per column, hitting a maximum output of 1000 sheets per minute. Flexible slicing sizes cover 9-inch and 12-inch formats, available in a 1-column or 2-column layout to match most standard foil dispenser boxes.
Key finished dimensions:
- Finished sheet size: 273mm × 228mm or 305mm
- Folded size: 135mm × 228mm or 305mm
Motor specification for 380V 50Hz power supply:
- Roots blower motor: 22 KW
- Main motor: 4 KW
- Constant tension motor:1 KW
Overall machine dimension: 4.5m×2m×2m, total weight 4500KG. It fits well inside medium-sized workshops without special foundation modification.
Why do converters choose this pop-up foil machine?
- Significant labor saving: Traditional production requires separate cutting and manual folding plus manual counting, which is labour intensive. This all-in-one machine counts sheets automatically. Operators only need to pack finished sheets into boxes, cutting down heavy repetitive manpower work.
- Stable running & consistent finished quality. Thin aluminum foil wrinkles and stretches easily. Combined constant tension control and vacuum folding ensure neat folds. V cross interleaving guarantees smooth pop-up performance, avoiding multi-sheet sticking issues. Sharp embossing also adds value for your private label product lines.
- Great flexibility for mixed order production. Quick changeover between different sizes and emboss patterns. You can handle large volume standard orders as well as small batch custom OEM jobs, expanding your order-taking capability.
Who is this machine for
- Existing aluminum foil processors wanting to add boxed pop-up foil to their product portfolio
- Food & baking consumable manufacturers aiming for in-house pop-up foil production instead of buying finished goods
- Factories doing OEM & private label service, needing flexible size and pattern options
If you are planning to set up production lines for boxed pop-up aluminum foil sheets, the FDF 680mm pop-up sheet machine offers you a proven, turnkey solution.
