>Alternatively, though, it might be possible to stiffen the foil by making the equivalent of corrugated cardboard out of it, maybe using aqueous boric acid (US$1.70/kg according to Potential local sources and prices of refractory materials) or borax as the glue. The surface tension of water is ample to hold aluminum foil in place until the water dries.
Hello Amazon? Billion dollar idea here. This needs more attention. You could have fully recyclable aluminum boxes instead of cardboard. Imagine your box supply chain literally being a circle.