Metalliser Process Flow — From Jumbo Roll to SAP Entry मेटलाइज़र प्रोसेस फ्लो — जंबो रोल से SAP एंट्री तक

Metalliser Process Flow — From Jumbo Roll to SAP Entry

If you've ever walked into a metallization plant, you'll see jumbo rolls moving like clockwork from one station to another. But what actually happens between the unwinder and the final SAP entry? In this blog, I'll walk you through every station of the metalliser process flow — the same flow used across the global flexible packaging industry.

🎯 Why Process Flow Matters

A metalliser is not just a single machine — it's a chain of 8-10 critical stations. A mistake at Station 2 shows up as a defect at Station 8. Understanding the full flow helps operators, supervisors, and managers troubleshoot faster, reduce waste, and improve A-Grade yield.

📋 The 8 Core Stations

The evaporation boats at Station 3 are the heart of the metalliser. Aluminium wire feeds onto ceramic boats heated to ~1500°C, instantly vaporising into a metal cloud that condenses on the cooled film above.

OD (Optical Density) is the single most important quality metric. Most metallised films target an OD between 1.8 and 2.6 — too low means poor barrier, too high wastes aluminium and weakens adhesion.

⚠️ Common Defects & Where They Originate

• Low OD patches → Boat temperature instability (Station 3)
• Pinholes → Contamination at pre-treatment (Station 2)
• Tunneling on rewind → Tension mismatch (Station 6)
• Edge wave → Cooling drum temperature gradient (Station 4)