Innovation in packaging decoration is no longer driven only by new shapes and colours. Behind every premium bottle, compact or component there is a production process that must be fast, repeatable and increasingly sustainable. In this context, dual sputtering technology is reshaping the way brands and manufacturers approach metallization and surface finishing.
By combining advanced automation, modular in-line coating systems and flexible handling solutions, companies like Tapematic are turning three-dimensional metallization into a strategic lever for competitiveness. Dual sputtering is not just another feature on a machine, it is a different way to design decoration, where creative freedom and industrial performance grow together.

From single sputtering to dual sputtering

Traditional sputtering systems rely on a single cathode, which deposits one metal layer at a time on the surface of the part. This approach is effective but limited when packaging requires multiple effects, complex structures or functional coatings with specific properties.
Dual sputtering technology, instead, introduces two fully independent cathodes inside the same in-line system. Each cathode can deposit a different metal layer within one continuous cycle. Decorative and functional coatings can therefore be combined without stopping the process or moving the parts to another machine.
The result is a compact and efficient workflow where metallization becomes both richer and more controlled. Layers can be combined to create subtle chromatic variations, mirror like finishes, soft metallic effects or highly resistant technical films. At the same time, the process remains stable, repeatable and suitable for large scale production.

Creative freedom for modern packaging decoration

In sectors such as cosmetics, beverage and premium consumer goods, packaging decoration has a direct impact on perceived value. Dual sputtering opens up a wide palette of visual and tactile possibilities that would be difficult or costly to obtain with single layer metallization.
Different metals can be combined to create gradients, contrasts and multi tone effects on the same component. Transparent or non metallized areas can coexist with reflective sections, giving designers more control over how light interacts with the object. Fine details, edges and geometries benefit from uniform coverage even on complex three dimensional shapes.
Since the process is integrated in a fully automated line, these effects are not limited to small series or special editions. They can become part of standard production, helping brand owners maintain consistent visual identity at scale while still offering distinctive finishes.

Functional coatings for demanding industries

Dual sputtering is equally valuable for automotive, pharmaceutical and industrial applications, where coatings must meet precise technical standards. Surfaces may need conductive layers, enhanced mechanical resistance or improved protection under specific conditions.
With dual sputtering, one cathode can deposit a decorative film while the second applies a functional layer with properties such as conductivity or mechanical durability. Both layers are applied in the same cycle, reducing handling, cycle times and potential damage to parts.
This combination of functional and decorative performance makes dual sputtering an essential tool for manufacturers working with strict requirements while also managing aesthetic expectations.

The role of Tapematic PST Line II in in-line metallization

At the core of Tapematic’s approach to packaging decoration is the PST Line II, a highly automated modular in-line system designed for continuous flow production. Instead of treating metallization as an isolated step, the PST Line II integrates different processes into a single, uninterrupted workflow.
Parts are loaded onto standard trays and move through cleaning, pre treatment, UV coating, sputtering metallization and curing without manual intervention. Each module is engineered to work in full synergy with the others, ensuring stability, minimal waste and short setup times.
This modular structure allows manufacturers to integrate dual sputtering modules directly into the line and expand capabilities over time. Systems can evolve according to production needs, allowing faster adaptation to new projects or decorative requirements.

Compact solutions with PST Line C

For companies that need the same process philosophy but within a smaller footprint, Tapematic offers PST Line C.
The PST Line C carries the same core coating and metallization principles found in PST Line II but in a more compact, cost effective layout. It is suitable for manufacturers aiming for high quality decoration without the need for a large modular system.
Dual sputtering technology can be integrated into both line types, enabling advanced decorative and functional results regardless of available space or investment level.

Standard tray concept for workflow stability

A fundamental element in dual sputtering performance is how parts are handled between processes. Tapematic applies the same standard tray concept across the entire PST Line range.
By keeping handling consistent, the system reduces misalignment issues, setup times and the risk of damaging delicate parts. Trays travel through each station without change, contributing to process stability and uniform results.
For dual sputtering specifically, stable tray handling ensures precise positioning of every component entering the metallization module. This consistency helps maintain uniform layers even at very high production speeds.

Automation, throughput and sustainability

Dual sputtering reaches its full potential when supported by advanced automation. Tapematic systems use smart handling, intelligent process control and optimised vacuum management to minimise manual operations.
High speed throughput becomes compatible with strict quality standards because every parameter is controlled. Lower rejection rates and predictable cycle times allow manufacturers to plan production with confidence.
At the same time, dual sputtering contributes to more sustainable manufacturing. Optimised energy use, resource conscious design and UV coating systems help lower waste and emissions. Combining multiple layers in a single metallization process reduces material consumption without compromising on visual or functional outcomes.

Industry 5.0 and human centred production

Dual sputtering is aligned with the principles of Industry 5.0, where automation and robotics work alongside people in a supportive role.
Integrated dual sputtering modules can interact with digital monitoring platforms, predictive maintenance tools and smart configuration systems. Operators supervise processes, refine settings and ensure quality rather than performing repetitive physical tasks.
Working conditions improve, efficiency increases and the overall production environment becomes safer and more ergonomic.

Dual sputtering as a new standard for packaging decoration

Dual sputtering is transforming modern packaging decoration by uniting creativity, efficiency and responsibility. The ability to deposit multiple metal layers in a single cycle expands decorative potential while meeting the technical demands of industries like cosmetics, automotive and pharmaceuticals.
Integrated with Tapematic PST Line II and PST Line C, this technology offers a flexible, scalable and sustainable approach to 3D metallization. Manufacturers can enhance product value, optimise energy use and streamline production all within a single, intelligent in-line workflow.
Dual sputtering is therefore emerging as a new benchmark for packaging decoration, raising the standards of precision, performance and industrial innovation.