Film Technology
End-to-end film processing—from extrusion to finishing—crafted to meet global packaging standards with exceptional clarity, strength, and performance.
Step 1: Film Production
Cast Extrusion
Our cast extrusion process melts plastic granules and pushes them through a flat die directly onto a chilled roller. This rapid cooling forms smooth, high-clarity films. Thanks to co-extrusion, we can produce multi-layer films (up to 5 layers), enabling excellent customizability in thickness (15–150 microns) and width (up to 2450 mm), ideal for food-safe and industrial packaging.
Step 2: Base Converting
Metallization
Using high-vacuum technology, a thin layer of aluminum is vapor-deposited onto the film. This process enhances barrier properties against oxygen and moisture while adding a reflective, premium appearance. Metallization can be full-surface or striped for window effects.
Step 3: Printing
Rotogravure Printing
Ideal for premium graphics, rotogravure printing uses engraved cylinders to transfer solvent-based inks directly onto the substrate. We can print up to 10 colors including backside applications, with options like cold seal or lacquer coating done inline.
Flexographic Printing
This high-speed, direct-pressure printing method uses flexible plates and quick-drying inks. Flexo printing supports a range of materials and is known for its cost-efficiency and speed — perfect for large-volume packaging runs.
UV Flexo Printing
A cleaner, solvent-free process using UV-curable inks and photopolymer plates. It allows up to 8-color printing and delivers sharp, photo-realistic detail with inline lacquering options, matching rotogravure in quality for many applications.
Step 4: Lamination
Extrusion Lamination
We use custom-formulated PE and PP extrusions to laminate multi-layer films with specific characteristics like sealability, transparency, and tensile strength—suitable for food and pharma-grade packaging.
Solvent-Based & Solvent-Free Lamination
Depending on application and sustainability goals, we offer both traditional solvent-based and eco-friendly solventless lamination. Both methods ensure excellent bond strength and compatibility across substrates.
Step 5: Converting & Finishing
Slitting
Large master rolls are precisely slit into narrower reels as per the customer’s packaging line requirements—ensuring smooth feed and reduced downtime.
Die Cutting
Using precision-made dies, we create custom shapes for lids or film applications. Embossing and deep-draw options are available for added texture and branding.
Reel Cutting
For roll-size customization, reel cutters split large printed or laminated rolls into multiple smaller reels. We offer variable winding directions, reel diameters, and core sizes tailored to client specifications.
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