Myth busting: what is metallized paper and exploring some ...

What is metallized paper?

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Metallized paper has a microscopically thin layer of aluminium (approximately 20-30 nm thick) evaporated onto its surface. The layer of aluminum gives the paper a bright, glossy surface which is visually appealing &#; meaning it&#;s ideal for packaging and labels.

Despite the addition of the aluminum layer, our products remain a paper material from a technical standpoint &#; because the aluminum layer is so thin, it doesn&#;t change the overall composition of the material.

While metallized papers were originally used for packaging because they offered shelf appeal, they also offer other benefits, namely some advantageous barrier properties, excellent resilience and approval for some direct food contact packaging. Metallized paper is  recyclable and an excellent alternative to metallized PET films for brands looking to reduce plastic.

Common misconceptions about metallized paper:

• It&#;s important to know that metallized paper isn&#;t anything like aluminum foil or aluminum paper laminate. Our products retain the texture and tactility of paper, with the addition of the very smooth, silver surface &#; imagine a kind of &#;mirror effect&#; on a paper substrate. 

• Metallized paper producers &#; like AR Metallizing &#; typically aren&#;t printers or converters. We are specialists in our field, and we produce large rolls of metallized paper. Printing and converting functions are carried out by trusted partners on the supply chain who create the packages or labels for end-users.

• We manufacture metallized paper in a single color: silver. It&#;s easy to make any type of metallic hue or shade by printing in transparent inks over the top of our papers, but we don&#;t produce in different colors.

How is metallized paper made?

1. We apply a base varnish to paper to increase gloss level and seal the pores inherent with the paper. The base varnish creates a very smooth surface for us to metalize.

2. After pre-coating, we metallized the paper. A microscopically thin layer of aluminium, approximately 20-30 nanometers thick, is evaporated on paper in a vacuum chamber.

3. When the paper has been metallized, we carry out post-coating and roll-finishing,  which provides a degree of abrasion resistance and a printable surface onto the metallized substrate.

Metallized paper is a special type of paper with a metallic layer deposited on its surface for decorative purposes. Metallized paper is a product that is coated with an aluminum layer and has a matte or glossy finish that provides decorative and protective properties to the product.

Metallized paper can be manufactured using two different systems.

Lamination

This process involves bonding the paper, usually uncoated, to a sheet of aluminum between 9 and 12 microns thick. Due to the high consumption of aluminum, this system is being used less and less.

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Vacuum Metallization

This system, which is most commonly used, involves heating aluminum or other materials in a vacuum chamber, causing them to evaporate or sublimate, and then depositing a thin coating on the surface of the coating. One can achieve a unique metallic finish on the package with a fraction of the aluminum content of conventional foil. 

The direct high vacuum process for producing metallized paper consists of three separate processes, namely

Varnishing

A thin layer of varnish is applied to the coated substrate in preparation for the subsequent metallization of the surface. The paper is pre-coated with lacquer to smooth the surface, act as a barrier layer between the paper and the metal coating and improve adhesion of the vaporized metal. The varnish is applied to the varnisher in a process similar to intaglio printing. After the varnish is applied, the paper passes through a hot air drying unit to remove the solvent from the varnish. Next, the paper passes through a set of freeze rollers to prevent the paper from sticking in the winder.

Metallization

This stage is probably the most critical point in the production process. Once the paper scents have been varnished, they are sent to the metallization area, where they are introduced layer by layer in order to apply the aluminum layer to the paper. The pre-coated paper is then metallized directly. The varnished paper is placed in a "metallization chamber" where the aluminum layers are applied through a vaporization or sublimation process. 

Lacquering

All metallized papers are then surface coated and rewetted as a final process. Once the reel is placed in the lacquering machine, the metallized paper is subjected to a corona process, which helps to fix the lacquer to the aluminum. Once the corona process is complete, the lacquer is applied using a gravure printing system and then dried using a hot air channel. When the product is colored, it is the lacquer itself that is colored with the final color of the product. The classic color is gold, but from a technical point of view, other colorants can be used if necessary.

Metallized The surface of the product is essentially plastic, or in other words, it is waterproof and non-absorbent. It provides a range of barrier properties to the coated paper, creating a barrier to light, water vapor, oxygen and odors.

Interesting appearance

Paper can also have special effects that can change the appearance of surfaces that are usually very smooth. Let's take a look at two of them.

Holographic effect

This effect can be achieved through a proprietary and patented process of micro-embossing, which is used to create the desired visual effect.

Holographic Metallized Paper

Embossing effect

This finishing is achieved through the physical treatment used in certain grades and carried out in an embossing machine.

In addition, from a printing standpoint, metallized paper is a premium facing material - it runs like paper, is smooth and easy to use, and offers excellent printability, high definition and text clarity. These properties make this substrate ideal for beer and food labels. Please contact YF to get your unique solutions!

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