When it comes to outdoor cooking, the best aluminum foil for BBQ might not be the first thing that comes to mind, but it’s a true unsung hero.
Whether you’re smoking ribs, wrapping a brisket, or making a quick cleanup job easier, the right foil can make a big difference.
Over the years, I’ve learned that not all foil is created equal, especially when you’re dealing with high heat and long cook times.
Key TakeAway
- For wrapping larger cuts, use the heavy-duty aluminum foil.
- For regular things such as foil boats, the bottom of the grill, etc., use the regular aluminum foil.
In this guide, I’ll walk you through what to look for and which brands I trust at my smoker.
Eddie’s Tip! I have seen people asking questions about this subject, and you can read my answers on the Can You Put Aluminum Foil On The Grill page.
Why Use Aluminum Foil in BBQ?
Aluminum foil can be used for a lot of things in the BBQ world:
- Heat retention for even cooking
- Moisture control, especially during long smokes
- Easy cleanup of grates, fireboxes, and drip pans
- Barrier from flare-ups when grilling fatty meats
- Perfect for foil packets (like veggies or sides on the grill)
And of course, it’s central to techniques like the Texas Crutch, where foil helps you through the stall during a brisket or pork shoulder smoke.
What to Look for in BBQ-Quality Aluminum Foil
If you’ve ever had foil tear mid-wrap or fall apart while you were wrapping meat, you already know why quality matters.
Here’s what to watch for:
1. Thickness (in mils or microns)
- Standard Duty (~0.0007″) – Fine for light jobs and foil packets
- Heavy Duty (~0.001″) – Good for most BBQ tasks
- Extra Heavy Duty (~0.0015″+) – Best for big cuts, high heat, and long cooks
2. Width and Roll Size
- 12-inch is common, but 18-inch rolls are ideal for wrapping briskets or covering wide surfaces.
- Bulk rolls (200–500 ft) are more cost-effective for frequent grillers.
4. Heat Durability
- Cheap foil can break down or tear, especially when wrapping hot food or lining fireboxes.
Best Types of Foil for BBQ (My Cases and Recommendations)
Although you can use the same foil for anything you are using it for, it is my experience that picking the right aluminum foil can make it easier.
Here is the short version!
For regular aluminum foil, I use the store brand from my local supermarket, and in my experience, I found no reason to spend more money on a top brand.
For heavy-duty, I tested many brands and have not found a lot of difference between brands.
Eddie’s Tip! I mostly order mine from Amazon, and you can find it by clicking here.
For Wrapping Large Cuts (Brisket, Pork Butt, Ribs)
- Go with extra heavy-duty foil. It handles juices, pressure, and lasts longer in my experience
Eddie’s Tip! I wrote a whole article on how to smoke a pork butt, and how I use aluminum foil for wrapping.
For Lining Grill Grates or Drip Trays
- Use wide, heavy-duty foil for fewer seams and full coverage.
- Makes cleanup a breeze after saucy rib sessions.
For Foil Packets (Veggies, Fish, Sides)
- Standard-duty foil works great here, especially when folded into packets.
- Non-stick versions prevent sticking with delicate foods like salmon.
For Smoker and Firebox Cleanup
Eddie’s Tip! I use aluminum foil for keeping the bottom of my grill clean, as you can read in this article: https://thegrillingdutchman.com/how-do-you-keep-the-bottom-of-a-bbq-clean/
I always lay a layer of aluminum foil on the bottom of my grill to make clean up a lot easier. Trust me on this one!
- Extra-wide rolls (18” or more) can line your lower chamber or ash tray, saving you time after a long cook.
Aluminum Foil vs Butcher Paper
I read that some people claim that you can use aluminum foil and butcher paper for the same things. I don’t agree with that.
Each of them has a “best use” and should be used for certain things. Aluminum foil or butcher paper used to wrap bigger cuts of meat results in a different outcome for moisture and bark.
Eddie’s Tip! When I’m smoking a brisket or Boston Butt, I always wrap it in extra heavy-duty foil once it hits 165°F. It holds the juices better, resists tearing, and gets me past the stall faster without turning my bark soggy.
Best Aluminum Foil for BBQ – My Experience
I’ve tried just about every type of aluminum foil on the market over the years. from store brands, restaurant-grade rolls, and everything in between.
The truth is, you don’t always need the most expensive option, but you do need one that can handle high heat and long cooks, and moisture.
One thing I look for is a metal edge on the box to tear off the aluminum foil. The cheaper brands use a cardboard edge, and I have not had good luck with these.
For big jobs like brisket or smoking a pork butt, I never mess around and go with Heavy Duty. For lining trays or making foil packets, a standard roll from Sam’s or Costco, or the grocery store, works just fine.
If you’re cooking outdoors a lot, invest in the wide rolls. Trust me, wrapping a full rack of ribs or a smoked pork belly, without double-layering, is worth every penny.
The right foil makes outdoor cooking easier, and when you’re working the smoker for 12 hours, you’ll notice the difference.
FAQ
Here are some questions I found that people have about the use of aluminum foil for BBQ and cooking.
Q: Is aluminum foil safe at 450 degrees?
A: Yes, aluminum foil is safe to use at 450 degrees. The melting point of aluminum foil is around 1220°F (660°C)
Q: Should aluminum foil be shiny side up or down?
A: Shiny side up or down does not make a difference. The shiny side is formed during the production process and does not affect the cooking process.
Q: What’s the difference between regular aluminum foil and heavy-duty aluminum foil?
A: The main difference between regular and heavy duty aluminum foil is the thickness of the foil
Q: Can I use aluminium foil on the barbecue?
A: Yes, you can use aluminum foil on a barbecue since it is safe to use up to 1220°F (660°C)
Eddie van Aken
Eddie van Aken brings years of experience from running a full-service restaurant, where he honed his skills with all types of kitchen equipment. His expertise extends to mastering the art of outdoor cooking, utilizing the right recipes to enhance flavors on grills and smokers. Eddie’s in-depth knowledge allows him to provide comprehensive grill reviews and valuable outdoor cooking tips, helping enthusiasts make the most of their grilling adventures. You can read more on the About page for Eddie van Aken