How We Improved Metalized Film Barrier by 10x
By moving from a two-step to a single-step in-line top-coating process performed inside the metallizing chamber, Celplast developed DURAMET, achieving up to 10x better barrier than standard metallized films.
Protect your Barrier
Even the best barrier layer can be compromised by tiny defects or scratches during processing. One effective approach involves protecting the metallized barrier with a top coat to prevent downstream damage.
Two Step Vs. In-Line
Celplast suspected that traditional two-step top-coat processes introduced pin-holing and scratch defects. The company developed a single-step in-line process that applies the top coat directly in the metallizing chamber. Testing confirmed that this method significantly improved barrier properties compared to the two-step approach, resulting in DURAMET: an in-line top-coated and metallized high-barrier film offering "up to 10-times" better barrier performance than standard metallized films.
The Results
Coated and metallized polyethylene terephthalate (PET) and oriented polypropylene (OPP) achieve barrier properties comparable to foil. Similarly, coated and metallized poly lactic acid (PLA) reaches barrier levels equal to or exceeding metallized PET, expanding potential applications for this material type. The single-pass process demonstrates substantially improved barrier properties across all tested film types compared to traditional metallization alone.