ˍIntegrated solution for

conversion of AlOx films

VACUUM METALLIZING

BOBST AlOx Conversion

www.bobst.com
Trends and requirements

ˍPackaging trends AlOx Conversion

& consumer requirements

>> Trends and
requirements

>> Packaging market

>> At a glance

>> Process know-how

Numerous consumer market research which is more environmentally friendly. >> Barrier performance
studies have shown a new trend for Food products that are well protected by
>> Laminate structure
convenience food coupled with the desire their packaging leads to products which
to see the content of the package being are kept fresher for longer, this has a >> Services
purchased. This has pushed converters positive effect by reducing the amount >>General services
and brand owners to actively seek viable of food waste. >>Connected Services
alternative packaging solutions to
There is also a trend in the market for
increase consumer appeal and maintain
packaging simplification, film down
product freshness.
gauging and a move away from PVDC
When it comes to high barrier and & EVOH coated or extruded structures.
transparency, AlOx coated films are a In addition Aluminium foil prices are
clear alternative due to their humidity increasing and there is mounting pressure
independence, cost savings, transparency, in the packaging industry to become more
microwaveability and high barrier environmentally friendly by reducing
properties which extends product shelf carbon footprint & CO2 emissions.
life. AlOx barrier coated films are found in
The future of laminate applications is
an increasing number of food packaging
virtually limitless; by combining different REQUEST
applications ranging from health
materials and their positive features using CONSULTING
conscious products such as healthy snack
state-of-the-art technology and specialist
bars to confectionary, liquid pouches and Print responsibly
knowledge; the BOBST Integrated Solution
microwaveable foods.
for AlOx Conversion is a perfect example Data is not binding.
Non-contractual pictures.
Recyclability and sustainability are key of such an application for its simplicity of The manufacturer reserves
trends with a move towards packaging use and fast route to market. the right to make
modifications without notice.
© BOBST SA 2019
BUWF-AL-EN-092019

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 Packaging market – Substrate processing

ˍCreating value AlOx Conversion

>> Trends and

requirements

>> Packaging market

Sustainability Expanding reach of added
>> At a glance
BOBST innovations Growing demand in the market for value coating
are driven by customer recyclable, reusable and compostable Barrier enhancement and high precision >> Process know-how
and brand owner needs. packaging solutions, to work towards a coating for high quality, high appeal >> Barrier performance
circular economy. products with extended shelf life to be
> READ MORE >> Laminate structure
used in a variety of industries including
Barrier solutions labels, medical, hygiene, cosmetics >> Services
Growing requirement for packaging with and industrial. >>General services
high barrier to oxygen and water to
>>Connected Services
extend shelf life. Unique combinations Partnerships to deliver new
of vacuum and wet coatings for faster innovative solutions
time-to-market. Working together to develop, test, refine
and certify new products and solutions.
Process experts and converters fulfill the
desired end product and meet evolving
market needs.

Cost reduction
AluBond® as an enabling technology to
higher performance, dyne level, adhesion
and barrier at a lower cost.

Print responsibly

Data is not binding.

Non-contractual pictures.
The manufacturer reserves
the right to make
modifications without notice.
© BOBST SA 2019
BUWF-AL-EN-092019

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 At a glance

ˍIntegrated AlOx AlOx Conversion

conversion solution
>> Trends and
requirements

>> Packaging market

>> At a glance

>> Process know-how

The BOBST simple and efficient AlOx In addition, the BOBST Integrated Solution for the conversion of AlOx >> Barrier performance
vacuum deposition process for single transparent barrier films incorporates the application of an off-line topcoat
>> Laminate structure
layer application onto clear films has been to protect and enhance barrier functionality during conventional conversion
well-established in the market for many processes such as printing and lamination. >> Services
years. The result is high barrier properties The process knowledge transfer, top coat formulation and conversion >>General services
with a thin inorganic oxide layer that know-how from one single supplier results in a faster time-to-market from >>Connected Services
provides excellent coating uniformity day one. The two-step process is extremely cost-effective and provides
and transparency. a wider window of operation with the vacuum coating process followed
by a topcoat applied in atmosphere.
Unlike other in-vacuum topcoat solutions, the BOBST solution works
at maximum operating speeds and results in maximum productivity
without compromising performance.

Pouch structure example

Food safety allowing Outside pouch

metal detection PET (12µm)
AlOx (Vacuum metallizing - EXPERT K5)
REQUEST
Topcoat (NOVA CO 750) CONSULTING
Ink (gravure or flexo press)
Low-cost, easy to operate Adhesive (Lamination - NOVA C0 750) Print responsibly

Data is not binding.

PE sealant (32µm) Non-contractual pictures.
The manufacturer reserves
Simple and effective the right to make
barrier protection modifications without notice.
© BOBST SA 2019
Inside pouch (food contact side) BUWF-AL-EN-092019

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Process know-how

ˍHigh barrier topcoated AlOx Conversion

AlOx film made easy

>> Trends and
requirements

>> Packaging market

>> At a glance

>> Process know-how

>> Barrier performance

PET/AlOx/Topcoat PET/AlOx
>> Laminate structure
B >> Services

>>General services
>>Connected Services

A
Topcoat

Unique coating formulation Two-step process

An organic topcoat layer is applied to encapsulate the thin This is a two-step process without compromise that requires
ceramic type AlOx barrier coating and provide increased relatively low capital investment, allows for a wide operating
flexibility to prevent initiation of micro-cracks and other defects window and has a low running cost. Two processes running
during standard conversion/handling processes resulting in at max capacity without compromising speed, barrier REQUEST
excellent product protection with high barrier properties. performance, quality or cost. CONSULTING

These are optimised tailor-made coating formulations that are Print responsibly
specifically designed to work in conjunction with the unique
Data is not binding.
BOBST AlOx process and provide protection to the film barrier Non-contractual pictures.
The manufacturer reserves
properties during all stages of the conversion process and also the right to make
give a barrier improvement in both oxygen transmission rate modifications without notice.
© BOBST SA 2019
(OTR) and water vapour transmission (WVTR). BUWF-AL-EN-092019

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 Process know-how

AlOx Conversion
The AlOx coated PET films are first produced on a BOBST vacuum metallization
platform (either an EXPERT K5 or VISION K5) the film is then topcoated on an AlOx >> Trends and
optimized BOBST Coating line (e.g. NOVA CO 750). Once coated, the film is then requirements

either gravure printed or flexo printed and is finally laminated on the NOVA CO 750. >> Packaging market

>> At a glance

>> Process know-how

AlOx vacuum metallizer Coating line
>> Barrier performance

>> Laminate structure

>> Services

>>General services
>>Connected Services

ROBUST AlOx CLEAR BARRIER FILM

The BOBST AlOx Integrated Conversion Solution enables film producers
and converters to produce high barrier transparent films for flexible
REQUEST
packaging (single layer topcoated or complete laminate structures) CONSULTING
with a robust structure and superior properties that can withstand
the aggressive mechanical stresses during some typical conversion Print responsibly
processes with minimal loss on barrier permeation performance.
Data is not binding.
Non-contractual pictures.
It is a game-changer in the packaging industry due to its simplicity The manufacturer reserves
the right to make
of use and operation resulting in outstanding barrier performance modifications without notice.
and flex crack resistance, yet totally transparent in a low cost process. © BOBST SA 2019
BUWF-AL-EN-092019

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 Barrier performance

ˍSuperior barrier AlOx Conversion

performance
>> Trends and
requirements

>> Packaging market

>> At a glance

>> Process know-how

The BOBST AlOx topcoated, printed and BARRIER TOPCOAT >> Barrier performance
laminated integrated film structure has
OTR improvement by factor > 10 WVTR improvement by factor ≈ 2
been extensively evaluated for durability 1.2 0.9
>> Laminate structure

and barrier permeation performance 0.8 >> Services

1.0
including the Gelbo Flex test before going 0.7
>>General services
to market. 0.8 0.6
>>Connected Services

OTR cm3/(m2 d)

WVTR g/(m2 d)
0.5
This test is used to simulate the strain the 0.6
0.4
packaging material may be exposed to 0.4 0.3
during further downstream processes 0.2
after lamination such as folding and 0.2
0.1
forming into packaging and when handled 0.0 0.0

during transport, storage and in the PET/AlOx Topcoat Printing PET/AlOx Topcoat Printing
Lamination Slitting Pouch making Lamination Slitting Pouch making
retail environment.
OTR performance after Gelbo Flex (laminate) WVTR performance after Gelbo Flex (laminate)
The Gelbo Flex test procedure has been 5 1.8

designed to determine structural durability. 1.6

After a pre-determined number of flexing 4 1.4

cycles, subsequent barrier measurements 1.2

REQUEST
OTR cm3/(m2 d)

will show if it can withstand this type

WVTR g/(m2 d)
3
1.0 CONSULTING
of repetitive flexural strain. 0.8
2
0.6 Print responsibly
The graphs show the OTR and WVTR values
0.4
Data is not binding.
of the barrier topcoated film through
1

0.2 Non-contractual pictures.

conversion and after 20 Gelbo Flex cycles. The manufacturer reserves
0 0.0 the right to make
0 2 4 6 8 10 12 14 16 18 20 0 2 4 6 8 10 12 14 16 18 20
modifications without notice.
Number of Gelbo Flex cycles Number of Gelbo Flex cycles
© BOBST SA 2019
Barrier topcoat Non topcoat Barrier topcoat Non topcoat BUWF-AL-EN-092019

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Laminate structure

The BOBST Integrated Solution results in downgauging of the film or has the AlOx Conversion

potential to reduce the number of layers in the laminate structure resulting

>> Trends and
in packaging simplification with a duplex laminate rather than the traditional requirements

triplex structure which translates in a reduction of conversion steps and >> Packaging market

lower production cost. >> At a glance

>> Process know-how

Weight reduction
>> Barrier performance

>> Laminate structure

The duplex laminate structure also offers TRIPLEX (Typical Structures) DUPLEX
>> Services
environmental benefits due to a reduced PET/Al foil/Sealing web (BOBST Innovative Approach)
material use and packaging weight. PET/AlOx/Topcoat/Print/Adhesive/
>>General services
PET(Printed)/Adhesive/MetPET/
It leads to a package which is more Sealing web >>Connected Services
Sealing web
environmentally friendly and sustainable
Less material (AlOx: 8-10nm vs
due to its higher yielding and chlorine-free
PVdC:1-2µm), light weight
chemistry. This also results in a reduced
carbon footprint.
PET Ink Adhesive PET AlOx Topcoat

RECYCLABILITY
This technology is the first step towards
packaging designed for recyclability; it
aims to divert packaging waste from
landfill or incineration and aid the creation
of a circular economy for plastic packaging.
REQUEST
CONSULTING
The BOBST AlOx Conversion process is
a great example of how innovation and Print responsibly
process technology together can meet
Data is not binding.
the needs of converters, brand owners, Non-contractual pictures.
Metallized PET Sealing web Ink Adhesive Sealing web
retailers and consumers. The manufacturer reserves
the right to make
modifications without notice.
© BOBST SA 2019
BUWF-AL-EN-092019

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General services

ˍMaintaining Maintenance Plus

–– Scheduled maintenance with
BOBST certified technicians
AlOx Conversion

excellence
>> Trends and
–– Preventative intervention, requirements

maximizing machine uptime >> Packaging market

–– Optimum performance over the
>> At a glance
equipment lifetime
>> Process know-how
Expert services for all your equipment.
> WATCH VIDEO
Improve your processes, boost your productivity >> Barrier performance

and enhance your expertise with a complete range >> Laminate structure
Approved parts and logistics
of services from BOBST. –– BOBST Original and Certified parts, >> Services

and consumables >>General services

–– Quality assurance, and extended >>Connected Services
maintenance intervals
–– Worldwide distribution, and full
availability where and when
you need it

> LEARN MORE

Machine upgrades
–– Additional features, configured for
your machine
–– Enhanced functionality, connectivity
and capability
–– Future-proofing your investment,
maintaining competitive advantage
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> LEARN MORE
Data is not binding.
Non-contractual pictures.
The manufacturer reserves
the right to make
modifications without notice.
© BOBST SA 2019
BUWF-AL-EN-092019

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 Connected Services

ˍSwitch on AlOx Conversion

digital transformation
>> Trends and
requirements

>> Packaging market

>> At a glance

>> Process know-how

BOBST Connected Services ensures your business is ready for the changing Remote Monitoring
world of digital manufacturing. Our range of apps and technical support –– Real-time production and >> Barrier performance
operating data
brings full connectivity to your equipment and processes – providing you with >> Laminate structure
–– Alerts and notifications when
a wealth of real-time data, analytical tools and expertise – helping you work >> Services
something happens
smarter and more productively. –– Enabling instant intervention >>General services

Downtime Tracking >>Connected Services

–– Detailed analysis on machine

Helpline Plus performance
–– Remote access intervention, –– Understand the root causes
with BOBST technicians of downtime
–– Expert support, eight hours a day, –– Enabling preventative intervention
five days a week and improved productivity
–– Maintain production, reduce
callouts by 80%
Connect Portal Please contact your local
–– Easy-to-access portal to data, BOBST representative for
reports and analysis service availability REQUEST SERVICE
–– User-friendly interface INFORMATION
–– Full connectivity and accessibility
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–– Access insights on the go with
> WATCH VIDEO Mobile Portal from your smartphone Data is not binding.
Non-contractual pictures.
The manufacturer reserves
the right to make
modifications without notice.
© BOBST SA 2019
BUWF-AL-EN-092019

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