Sustainable Metallized Paperboard Laminate from AR ...

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The environment plays a more important role than ever before in how people think about packaging, from the design to the materials selected. Metallized paperboard laminate from AR Metallizing (ARM) is a great choice for packaging today. ARM’s metallized papers offer a way to achieve a distinctive, metallic finish on the packaging of your products with only a fraction of the aluminum content and without any films or foils.

"Downgrading the board’s quality will result in significant cost savings, as will lowering the total weight of the box."

Today, metallized boxes consist of a first-grade board with a smooth surface laminated to metallized PET film. ARM’s metallized paperboard laminates are made of low-grade, recycled board laminated to a 53gsm-thick metallized paper. The smoothness of the paper will cover the low surface quality of the board. Downgrading the board’s quality will result in significant cost savings, as will lowering the total weight of the box. Why? Metallized PET film does not add any stiffness, while 53gsm fiber paper does. First-grade board with 10gsm of clay coat is less stiff than its uncoated recycled alternative.

Certification by the Centre Technique du Papier in Grenoble, France, has proven ARM’s metallized paperboard laminate is 100% re-pulpable compared with only 91% for the traditional metallized film laminates. The reason for this is that the re-pulping plant will sieve out the polluted pulp. In the case of metallized film laminates, a minimum of 9% will be contaminated foil waste that can only be placed in landfill or incinerated at a high cost. In the case of ARM’s metallized paperboard laminate, the initial pollution will only be 3%. Once further analysed, this 3% consists of long fiber pulp that can also be re-used as pulp. With metallized paperboard laminate, there is no landfill waste or CO2 generation. Each 1kg of non re-pulpable waste generated by metallized PET will produce 1.15kg of CO2 after incineration.

"The use of metallized paperboard lamination also results in a reduction in glue curing time, saving on oven energy."

Converters will also notice an increased efficiency in their production lines when running metallized paperboard laminate compared with metallized PET. Metallized paperboard lamination runs faster due to better reel tension management. The use of metallized paperboard lamination also results in a reduction in glue curing time, saving on oven energy. There is less waste in the production process when using metallized paperboard laminate because this product runs like regular paper, not like film. The die-cutting process is faster because the knife is cutting through paper not film. This also yields a lower knife consumption rate. Lastly, ARM’s metallized products are printable in nearly all technologies, including conventional offset, heliogravure and flexo, avoiding the costly addition of an overlay coating on PET.

Another advantage of ARM’s metallized paperboard laminate is that the same sustainable technology applies to the HoloPRISM® holographic metallized paperboard. ARM has won numerous awards with various projects using HoloPRISM. End users can have stronger brand identity and greater shelf appeal using ARM’s line of holographic and metallized paperboard laminates while remaining environmentally responsible.

Metallized Paper Suppliers share with you about the production of metallized paper and its use, hope it will be helpful to you

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

Metallized Paper

There are two different systems available for manufacturing metallized paper:

If you want to learn more, please visit our website Waterproof Vacumm Metallized Paper.

Lamination method

This process consists of gluing the paper to a sheet of aluminum with a thickness between 9 and 12 microns. Due to the high consumption of aluminum, this system is being used less and less.

Vacuum Metallization

This system is the most commonly used and consists of heating aluminum or other materials in a vacuum chamber to vaporize or sublimate them and deposit a thin layer of coating on the surface of the coated substrate. In this case, the main advantage is that 300 times less aluminum is used than in the previous case.

In both cases, this type of substrate provides a solution to achieve a unique metallic appearance on packaging with a fraction of the aluminum content of conventional aluminum foil.

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

As mentioned earlier, the best method for producing metallized paper is through vacuum metallization. The process of producing Metallized Paper by the direct high vacuum method consists of three separate processes, namely the following:

Varnishing

A thin layer of varnish is applied to the coated substrate to prepare the surface for the subsequent metallization. The paper is pre-coated with varnish, which serves to smooth the surface of the paper in order to act as a barrier between the paper and the metallized layer and to improve the adhesion of the vaporized metal. The varnish is applied in the varnisher by a process similar to intaglio printing. Once the varnish is applied, the paper is passed through a hot air drying unit to remove the solvent from the varnish, thus drying the paper until it has a moisture level between 2-3%. Next, in the same varnisher, the paper passes through a set of freezing 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 sheets have been varnished, they are sent to the metallization area where they are introduced one by one 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 layer is applied through a vaporization or sublimation process.

Varnishing

All metallized papers are subsequently surface coated and re-moisturized as a final process. Once the reel is placed in the lacquering machine, the metallized paper is passed through a corona treatment to promote the fixation of the lacquer on the aluminum. This corona treatment serves to increase the surface tension of the metallized surface. Once the corona treatment has been applied, the lacquer is applied using a gravure printing system just like in a varnish machine and subsequently dried using a hot air tunnel. When the product is colored, it is the lacquer itself that is tinted 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. After drying, the metallized paper is passed through a cooling roll followed by a water and back treatment. This is to ensure that the paper has the final moisture required for the finished product and remains flat when converted into sheets or labels. The coating protects the aluminum from damage and serves as a print receptive primer for a variety of printing applications. A thin layer of lacquer is applied to give the paper its final characteristics, such as printing characteristics, colors such as gold leaf or a matte/glossy finish. The resulting product can be recycled just like any other specialty paper.

The metallized surface of Wet Strength Metallized Paper is plastic in nature, or in other words, it is water resistant and non-absorbent. It provides a range of barrier properties to the coated paper, creating a barrier to light, water vapor, oxygen and odors.

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