UV-cured coatings are widely used across industries for their rapid curing, environmental benefits, and high-quality finishes. When it comes to flexible packaging, however, ensuring surface durability is more complex. Tapematic, a leader in automated surface treatment technologies, addresses this challenge through its PST Line II and PST Line C systems—offering integrated solutions for precise UV coating and curing even on delicate, non-rigid materials. With the right combination of surface preparation, coating control, and curing precision, Tapematic ensures long-lasting, high-performance finishes on flexible packaging components.

PST Line II: high-efficiency coating for complex packaging

At the center of Tapematic’s offering is the PST Line II—a modular, fully automated inline system designed for the high-speed application of UV coatings and metallization on three-dimensional surfaces. Though often associated with rigid packaging, the PST Line II is equally capable of handling flexible substrates, thanks to its advanced control systems and customizable process configurations.
Its modular design includes:

- Integrated pretreatment module for surface preparation
- Robotic UV spray coating unit
- Vacuum metallization chamber (if required)
- UV curing section for immediate polymerization

This architecture ensures each layer of coating is applied and cured under optimal conditions, resulting in a surface finish that is both durable and visually appealing.

Importance of pretreatment for flexible materials

Surface durability begins with preparation. Flexible substrates often pose adhesion challenges due to their composition, surface energy, and susceptibility to contamination. Tapematic solves this by integrating a dedicated cleaning and pretreatment module before coating.
Key actions include:

- Removal of dust, residual from injection process and particulates
- Elimination of static charge that may repel coating
- Surface activation to enhance UV varnish adhesion

Unlike systems that require a cleanroom, Tapematic’s inline pretreatment process provides a controlled environment without the overhead and complexity of external infrastructure—perfect for high-speed packaging lines that demand reliability and simplicity.

Precision UV spray coating for uniform coverage

One of the most critical steps in ensuring long-lasting UV-cured surfaces is achieving a uniform coating layer. This is particularly challenging with flexible packaging, which may deform or vibrate during processing.
Tapematic’s robotic spray coating unit addresses these issues through:

- Real-time adaptive spray path control
- Programmable parameters based on material geometry and flexibility
- Controlled airflow to stabilize components during application

These features ensure that the UV varnish is evenly distributed across the surface, maintaining consistent thickness and eliminating weak spots prone to cracking or peeling.

Real use case: flexible cosmetic closures

A cosmetics manufacturer producing flexible dispensing closures turned to Tapematic to improve the durability and visual appeal of its packaging. Their previous UV finishing process resulted in inconsistent gloss and cracking under mechanical stress.
After integrating the PST Line II:

- UV varnish adhesion improved by 40% due to optimized pretreatment
- Surface cracking was virtually eliminated
- Gloss levels remained consistent across production batches
- Line throughput increased by 30% with reduced rejection rates

This case demonstrated that flexible packaging can meet luxury standards when processed with the right technology.

UV curing: instant, efficient, and precise

Durability also depends on how well the coating is cured. Tapematic’s UV curing modules use high-intensity UV light to instantly polymerize the varnish, locking in its properties before any mechanical stress or deformation can occur.
Tapematic systems allow for:

- Adjustable UV intensity based on material sensitivity
- Uniform curing across the surface, including edges and contours
- Low thermal load, preserving substrate integrity
- Inline monitoring of curing performance

For flexible materials, this controlled curing approach ensures that the varnish remains elastic enough to bend without cracking, while still providing excellent resistance to abrasion, moisture, and chemicals.

PST Line C: compact solution for flexible packaging lines

Manufacturers with limited floor space or lower production volumes can benefit from the PST Line C, Tapematic’s compact, non-modular coating system. It includes pretreatment, UV coating, and curing in one integrated unit and supports a wide variety of shapes—including flexible and semi-rigid packaging components.
The PST Line C is ideal for:

- Pilot runs of new packaging designs
- R&D departments validating coating performance on flexible substrates
- Smaller production facilities seeking efficiency without compromise

It delivers the same surface durability and coating precision as the PST Line II, scaled for different operational needs.

Sustainable UV coatings for modern packaging

In addition to their technical performance, UV-cured coatings offer a more sustainable alternative to traditional solvent-based varnishes. Tapematic’s systems are designed to maximize these benefits while ensuring surface durability.
Sustainability features include:

- No VOC emissions during coating or curing
- Reduced material waste through precise spray control
- Low energy consumption due to instant curing
- Elimination of post-curing ovens and solvent handling systems

These advantages support manufacturers in meeting environmental regulations and reducing the carbon footprint of their packaging processes.

Process automation for quality and repeatability

Consistency is key in surface finishing, especially when dealing with flexible materials that may react unpredictably. Tapematic’s automation software ensures that every part of the process—from pretreatment to coating to curing—is optimized and repeatable.
Automation benefits include:

- Real-time adjustment of spray and curing parameters
- Traceability of every production batch
- Predictive maintenance to avoid unplanned downtime
- Seamless integration with MES and Industry 4.0 platforms

This digital layer ensures that the durability of UV-cured surfaces is maintained, even under high-speed production and complex part geometries.

Compatibility with metallization and protective topcoats

For flexible packaging that also requires a metallic or decorative finish, Tapematic integrates vacuum metallization (via sputtering) between the UV base and topcoat layers. This multi-layer approach delivers a stunning aesthetic while preserving surface integrity.
In this case, the process flow typically involves:

- Surface pretreatment
- UV base coating application
- Vacuum metallization
- UV protective topcoat
- Final UV curing

The topcoat adds abrasion resistance, seals the metallized layer, and enhances the visual depth of the finish—ensuring long-lasting performance even on bendable substrates.

Enabling innovation in flexible packaging design

Tapematic’s technology empowers designers and manufacturers to explore new shapes, materials, and finishes in flexible packaging—without compromising durability or production efficiency. From luxury cosmetic tubes to specialized pharmaceutical caps, UV-cured coatings applied through Tapematic’s systems support the demands of innovation while delivering consistent, high-performance results.