Developments in Metallised Papers for Packaging

68 Pages·0.309 MB·English

by  Pira International Ltd

Developments in Metallised Papers
for Packaging
Arthur Riley
Published by
Pira International Ltd
Cleeve Road, Leatherhead
Surrey kt22 7ru
UK
T [phone]
F [phone]
E [email protected]
W www.piranet.com
The facts set out in this publication Pira International Ltd acknowledges product, service and company names referred to
are obtained from sources which we in this report, many of which are trade names, service marks, trademarks or registered
believe to be reliable. However, we trademarks.
accept no legal liability of any kind
for the publication contents, nor any
information contained therein nor
conclusions drawn by any party from it.
No part of this publication may be
reproduced, stored in a retrieval
system, or transmitted, in any form or
by any means, electronic, mechanical,
photocopying, recording or otherwise
without the prior permission of the
Copyright owner.
ISBN 1 85802 521 4
© Copyright
Pira International Ltd 2006
Head of publications and events
Philip Swinden
[email protected]
Publisher
Rav Lally
[email protected]
Head of editorial
Adam Page
[email protected]
Global editor
Nick Waite
[email protected]
Head of US publishing
Charles E. Spear, Jr.
[email protected]
Assistant editor
Claire Jones
[email protected]
Customer services manager
Denise Davidson
[email protected]
T [phone]
Typeset in the UK by
Jeff Porter, Deeping St James,
Peterborough, Lincs
[email protected]
Contents
List of tables iv Demand for good barrier protection 37
List of figures v Decorative drivers 38
Executive summary vii Cost saving 39
1
Environmental concerns 40
4
Introduction 1
Objective of the report 1 Cutting-edge technology
Scope 1 developments: process, machinery
Methodology 1 and consumables 43
Metallisation – what is it? 1 Metallised paper and paperboard 43
List of definitions 2 Pattern metallising 44
2 Ceramic boats 44
Aluminium wire 45
Electron beam accelerators 45
Electron beam curing 45
The competitive landscape 9 Electron beam evaporators 46
The value chain 9 Drying 47
Brand authenticity – undisputed Metallisation of paper and paperboard 47
credibility 13 Direct vacuum metallisation –
Metallised paper and paperboard 14 traditional 48
The metallising industry 17 5
Company news 24
Europe 24
North America 29
Rest of the world 32 Substrate developments 53
3
Paper and paperboard manufacture 53
The process 53
Cast coating for high-quality surface for
metallising 55
Development drivers 37 Label papers 56
Brand protection 37
Page iii © Copyright Pira International Ltd 2006
List of tables
2.1 World markets for metallised paper 2.6 Selection of suppliers to the
and paperboard 15 metallising industry from the rest of
2.2 E uropean consumption of metallised the world 32
paper and paperboard, 2000 15 5.1 Typical paper and paperboard
2.3 Metallised barrier papers 16 weights and potential uses for
2.4 S election of suppliers to the paper metallised applications 53
and paperboard metallising industry
in Europe 23
2.5 S election of suppliers to the paper
and paperboard metallising industry
in North America 28
PPaaggee iivv ©© CCooppyyrriigghhtt PPiirraa IInntteerrnnaattiioonnaall LLttdd 22000066
List of figures
2.1 Metallising of paper and board value 4.2 The metallising process 49
chain 11 4.3 The indirect transfer metallisation
2.2 Brand owner use of holograms process 51
worldwide, by geographic region 20 4.4 Typical metallised substrate
4.1 Vacuum metallising chamber 49 structure 52
PPaaggee vv ©© CCooppyyrriigghhtt PPiirraa IInntteerrnnaattiioonnaall LLttdd 22000066

Executive summary
The following report covers the metallised paper and paperboard industry. It discusses the
importance of paper and paperboard substrates, vaporising systems, coating technology,
drying, and control of the metallised aluminium layer. The report also concentrates on the
main players in the market and technology and market developments which are ensuring
the industry will stay relatively buoyant.
Chapter 1 – Chapter 1 explains the objectives of the report, the scope and the methodology used, it
Introduction gives a brief introduction to metallisation and lists definitions of the terminologies used.
Chapter 2 – The The value chain is discussed, explaining how the machinery, the consumables, where they
competitive are produced and line efficiencies all contribute to the overall costs.
landscape Numbers of metallising companies are decreasing in North America and Europe. The
small, inefficient companies are being swallowed up by large companies such as Vacumet
– the largest paper metalliser in North America.
Threat to the established North American and European metallising companies is
coming from China and India. These regions are selling metallised paper and paperboard
into the established markets at prices which compete with the cost of manufacture, never
mind the selling price, reducing profit in established producer markets.
The main markets for metallised papers are beverage bottle and jar labels, both for
non-returnable and returnable packaging, and inner liners for the soft and rigid cigarette
pack market. The inner liner for cigarettes is dependent on continental preference, often
based on price of aluminium/paper laminate versus metallised paper. Australia and North
America favour the laminate, while in parts of Europe (especially where environment –
recycling, re-pulping and biodegradation – are important) flexible packaging opportunities
are reported to be growing for twist-wrap, butter and margarine wrap, lidding and flow-
wrap applications.
The main market for metallised paperboard is for high-value products packed in
cartons, such as confectionery, spirits and sparkling wines such as champagne. Other
market opportunities include blister-pack backing cards and packaging for impulse items
such as razor blades.
The market share of metallised papers and paperboards is reported to be increasing
year on year at over 2%. Europe is estimated to be the largest market for metallised paper
and paperboard. Metallised films represent the largest segment of the metallising market.
Metallised papers account for approximately a third of the market, with paperboard
representing a much smaller segment. Major applications of metallised paper include
beverage labels, confectionery wrap and inner liner.
The competition from aluminium laminates, metallised plastics, metal sheen inks and
hot foil stamping is growing, though all metallising methods have their place.
The need to protect and enhance the brand image is playing an important role in
the increase in market potential for metallised papers and boards, especially in the bottle
label market. Holographic designs are adding to the potential for papers and paperboard,
Page vii © Copyright Pira International Ltd 2006
Developments in Metallised Papers for Packaging
Executive summary
some being used for anti-counterfeiting and tamper-evident features on cartons and
flexible packaging.
The number of companies supplying metallised paper and paperboard to the industry
are restricted. The main vacuum metalliser in North America is claimed to be Vacumet
(probably the largest in the world). There are other suppliers worldwide, such as Dunmore
Europe, Ahlstrom, Alupa and Metallised Products. China, India and Indonesia all have
suppliers of metallised paper and board. All are looking to more developed markets to sell
their products. In Australia there is one main supplier of metallised paper and paperboard
– Optimet Metallising Pty Limited. For information concerning global suppliers of
metallised paper and board, raw materials, consumables and equipment, please refer to
Tables 2.4–2.6 (pages 24–32).
Chapter 3 – In a recent US pole carried out within the metallising industry, the main drivers were
Development identified as surface treatment, competing technologies, throughput and substrate
drivers developments.
Unlike metallised polypropylene and polyester films, metallised paper and paperboard
packaging does not exhibit overall barrier properties, with one known exception
– Dunmore Europe, which offers metallised barrier paper. Most metallised papers are
used for aesthetic purposes, especially when holographic decoration is used; the barrier
properties are supplied by the substrate and the lacquers used. Metallisation, however,
does provide a good light barrier. When specialty papers such as glassine are used, grease,
gas permeation, and water and moisture resistance can be improved. The low bulk density
characteristics of paper and the quality of print, especially via sheet-fed offset lithography
printing of clay-coated paper, is combating any challenge from plastic and aluminium in
the decoration on beverage packaging.
Metallisation methods of paper are via direct thermal, vacuum evaporation of
aluminium, or transfer of the metal deposition from a plastic film carrier onto the
paper or paperboard substrate. Electron beam thermal deposition has been used, but
much of the industry is reported to be using resistance heating. There has been little
reported development in the metallised paper and paperboard market. The industry is
very protective of the few developments which have been made. Most of the notable
developments have been in the lacquers used and an increase in efficiency due to larger,
in-line pre-coating, drying, metallising and over-lacquering systems.
Electron beam curing of lacquers is increasing, allowing metallised coatings to
be manufactured with high gloss levels and very low solvent retention levels. This has
enabled the industry to move into the general packaging market, with minimal risk of
taint and odour issues.
Metallisation of paper requires the moisture to be driven out of the paper prior to
metallising, and the metallised paper to be remoistened to ensure it does not curl in
storage. Drying processes have improved, ensuring that low levels of moisture (2–4%) are
present during the metallising process. Cryogenic gases are introduced, contained within a
Page viii © Copyright Pira International Ltd 2006
Developments in Metallised Papers for Packaging
Executive summary
small-bore tube, to ensure that the remaining moisture in the paper, which is vaporised in
the vacuum chamber, does not reduce the high vacuum, resulting in reduced efficiencies.
The vaporised moisture turns to ice on the tubing and is removed at the end of the
metallising cycle.
The main development drivers, however, are market needs, cost savings and, in some
countries, the need for more environmentally acceptable packaging.
Pattern metallisation is now developing. This will have a direct effect on the options
available for decoration. Currently it is being developed for plastic films, but surely it will
not be long before it is applied to metallisation of paper substrates.
Chapter 4 – Cutting- Metallising machinery is getting larger, as too is coating and processing equipment.
edge technology Electron beam vaporisation is starting to replace standard metallising technologies.
developments Electron beam is also finding more use in the curing of 100% lacquers, increasing
the speed and efficiency of the process and providing substrates with very low taint and
odour characteristics.
Direct metallisation of paperboard is increasing and competing directly with transfer
metallised substrates, providing the same smooth gloss, metallic finish at comparable cost.
Coating machines are getting larger, becoming more compatible in deckle with the
metalliser.
Ceramic evaporating boats are being developed which improve the quality and
efficiency of the metallisation process. There are now aluminium wires available which will
give a gold effect to the metal deposition.
The number of cast-coated paper suppliers is diminishing as better quality on-
machine coatings are being accepted by the metallising industry and brand owners as
technically competitive. Price rises in the paper industry are also causing brand owners to
look for less expensive alternatives without loss of quality.
The metallised paper industry is being challenged by the metallised film industry.
Metallised plastic films are being laminated to plain paperboard, producing a more cost-
effective package that gives an excellent appearance. Holographic presentation is also
very good. However, this could well change when North America realises that plastic films
laminated to paper are both difficult and not commercially viable to recycle. Metallised
paper and board is very acceptable to recycling companies and can be included in the
normal waste stream. Holograms are also possible on metallised paper and paperboard,
and paper laminates.
Holograms are growing fast in the decorative and security markets. The largest
percentage increase in holograms is in metallised films, but paper and paperboard
holographic packaging are finding new markets in the decorative and security markets.
Chapter 5 – On-machine coating and drying techniques are improving in the paper industry, making
Substrate the metalliser less reliant on more expensive, cast-coated papers. Special wet strength
developments and alkali resistant papers are continually being developed for the label market.
Page ix © Copyright Pira International Ltd 2006
Developments in Metallised Papers for Packaging
Executive summary
Supercalendered papers such as glassine are now available, providing a substrate which,
when metallised, provides light, grease, moisture and gas barriers. This has enabled
metallised paper substrates to be used for butter wrap and flexible packaging where the
product needs protecting.
Page x © Copyright Pira International Ltd 2006