Bobsts Vacuum Tech Transforms Packaging Industry

Lausanne, Switzerland – In an era of globalization and rapid technological advancement, innovations in materials science are transforming industries at an unprecedented pace. Among these, vacuum coating technology stands out for its unique advantages, demonstrating remarkable potential across packaging, decorative, security, and high-tech sectors. As a global leader in vacuum coating and metallization solutions, BOBST leverages its technical expertise and industry experience to drive advancements in vacuum coating technology, delivering exceptional value to clients worldwide.

Vacuum coating, also known as vacuum metallization, is a process that deposits an ultra-thin layer of metal (typically aluminum) or other coatings onto material surfaces. The technique involves evaporating coating materials in a vacuum chamber, allowing them to condense onto a substrate roll to form a uniform, dense film. Its applications span everyday items—from beer labels to potato chip bags—showcasing its versatility in packaging and decoration.

Compared to traditional coating methods, vacuum coating offers distinct advantages:

• Ultra-Thin Layers: Coatings range from nanometers to micrometers in thickness, adding functionalities like barrier properties, conductivity, or reflectivity without significantly increasing weight or volume.
• Superior Performance: The vacuum environment ensures uniform, dense coatings with enhanced durability and precision.
• Eco-Efficiency: High material utilization and minimal waste align with sustainable production goals.

BOBST’s vacuum coating machines, also termed metallizers or barrier coaters, operate with a vacuum chamber pressurized to 0.0005 millibar. Inside, aluminum wire is fed into resistance-heated evaporators, where it melts and vaporizes. Flexible substrates pass through the evaporation source at speeds up to 1,000 meters per minute, forming a metallic layer as aluminum condenses onto the cooled drum-supported material.

The precision-driven process involves five critical stages:

1. Vacuum Environment: Advanced pumping systems evacuate the chamber to minimize gas interference, ensuring optimal coating adhesion and quality.
2. Evaporation Source Heating: High-quality materials and controlled heating systems guarantee consistent metal vapor production.
3. Substrate Handling: Tension-controlled rollers guide substrates at high speeds while cooling drums maintain temperature stability for uniform deposition.
4. Plasma Treatment (Optional): Radiofrequency or microwave plasma units pre-treat surfaces to enhance adhesion and barrier performance by removing contaminants and activating molecular sites.
5. Coating Formation: Real-time sensors and algorithms adjust parameters like evaporation rate and substrate speed to achieve precise thickness and uniformity.

BOBST’s plasma systems bombard substrates with ions, electrons, and radicals to:

• Clean Surfaces: Remove moisture and contaminants via chemical reactions.
• Activate Molecular Sites: Increase surface energy for better coating adhesion.
• Modify Chemical Properties: Introduce polar groups to strengthen substrate-coating bonds.

This treatment significantly improves oxygen and moisture barrier properties, expanding applications in sensitive industries like pharmaceuticals.

BOBST’s technology reduces oxygen and water vapor transmission to levels rivaling glass and metal containers, extending shelf life while enhancing aesthetics. Key uses include:

• Food Packaging: Metalized films preserve crispness in snacks and freshness in coffee by blocking light and air.
• Pharmaceuticals: Coatings protect tablets and IV bags from humidity and contamination.
• Cosmetics: Luxe metallic finishes elevate brand appeal while safeguarding formulations.
• Industrial: Conductive substrates enable electronics; energy-saving films improve building efficiency; anti-counterfeiting features secure products.

With over a century of expertise, BOBST delivers:

• High-Speed Production: Up to 1,000 m/min throughput reduces costs.
• Premium Quality: Advanced controls ensure defect-free coatings.
• Reliability: Robust components minimize downtime.
• Customization: Tailored solutions address niche requirements.

BOBST continues to innovate, focusing on:

• Higher production speeds and automation.
• Enhanced coating functionalities (e.g., conductivity, reflectivity).
• Greener processes with reduced emissions.
• AI-driven control systems for smarter operations.

By pushing the boundaries of vacuum coating, BOBST empowers industries to reimagine material capabilities—one thin film at a time.