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How does metallized vacuum vaporisation work?

Author: Justin

May. 06, 2024

65 0 0

How does metallized vacuum vaporisation work?

  • Precoating: In this initial stage, the paper's pores are sealed with a base varnish. This step ensures a smooth surface and enhances the gloss level. Additionally, paper rolls are spliced together to maximize production efficiency.

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  • Metallization: The aluminum is then heated in a vacuum chamber until it vaporizes, creating a fine coat on the paper rolls using specialized machinery. The aluminum layer is uniformly thin, at around 20 to 30 nanometers—considerably thinner than standard aluminum foil or metallized PET film.

Metallized paper: How is it produced and how can it be used?

A metallized paper is a product that features a matte or gloss finish achieved by coating the surface with a layer of aluminum. This process not only imparts decorative qualities but also added protection.

 


Two primary methods are employed for creating metallized paper:

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Lamination

In lamination, a non-coated paper is glued to a thin sheet of aluminum, typically between 9 and 12 microns thick. While this technique is being used less frequently due to its high aluminum consumption, it remains a viable option.

Vacuum Metallization

Widely adopted, vacuum metallization involves heating aluminum or another material in a vacuum chamber until it vaporizes or sublimates, depositing a thin layer on a coated substrate. Notably, this method consumes 300 times less aluminum than lamination.

Both methods yield a substrate with a distinct metallic finish, ideal for packaging, and employing much less aluminum than traditional foils. Here are further details on the vacuum production process:

 

What is a vacuum production method and what does it involve?

As noted, the vacuum production method is the preferred approach for creating metallized paper. This high-vacuum process encompasses three primary stages:

Varnishing

A thin varnish layer is first applied to the coated substrate, smoothing the surface and improving the adhesion of the vaporized metal layer. Applied using a process akin to gravure printing, the varnish prepares the substrate's surface by acting as a barrier. After varnishing, the paper dries in a hot air unit, adjusting its moisture content to between 2 and 3%, before being cooled through refrigerated rollers.

Metallization

This critical stage involves sending the varnished paper to the metallization area, where a layer of aluminum is applied. In the metallization chamber, pre-coated paper is subjected to vaporizing or sublimating aluminum, resulting in a uniformly thin metallic coat.

Lacquering

Finally, metallized papers are re-moisturized and top-coated. The lacquer, often colored, like the classic gold, is applied via gravure and dried through hot air tunnels. This step protects the aluminum and serves as a primer for printing applications. The final product is waterproof, non-absorbent, and offers barrier properties against light, water vapor, oxygen, and odors.

The metallized paper is recyclable akin to other special papers. The distinct surface benefits make it ideal for various packaging needs.

 

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