Vacuum coating and metalizing is the process of adding a thin film of aluminum or another coating to a material.
in principle, the process calls for the evaporation of the coating material inside a vacuum chamber, after which it condenses onto a web of the substrate as it passes through.
paper and film metalizing is utilized in the packaging and decorative market segments. the barrier and decorative markets are noted for their wide variety of products from beer labels to chip bags.
inside this chamber, aluminum wire is fed onto individual, resistance-heated inter-metallic evaporators, where the aluminum becomes molten and evaporates.
the flexible substrate, supported on a chilled process drum, passes over the evaporation source at speeds of up to 1000 m/min. the aluminum vapor condenses onto the substrate and so creates the coating layer.
a plasma treatment unit can also be used as part of a vacuum coater system in order to enhance metal adhesion and/or to improve the substrate's qualities as a barrier against oxygen and water vapor transmission. here, the surface of the web is hit by plasma just prior to the coating process.
the plasma is formed by applying an electrical voltage to a gas, or combination of gases. in addition to removing moisture and other contaminants, plasma treatment acts to increase the number of nucleation sites by the introduction of polar groups, resulting in a coating with a homogeneous surface morphology and fewer defects.
the vacuum coater is used to deliver aesthetic improvements to flexible substrates and/or to reduce oxygen and water vapor transmission to levels similar to that of glass and metal containers. this delivers improved packaging performance, extends pack shelf life, and maintains the quality of the packaged product.
the process can also be used to produce substrates that conduct electricity, save energy, control light transmission or reflection, and which can even help prevent counterfeiting or theft.
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