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How in-line systems lower operational costs without compromising quality
Discover how in-line systems reduce operational costs in packaging decoration while maintaining high quality, efficiency and sustainability.
In many industries, packaging decoration is both a strategic asset and a significant cost driver. Brands demand visually flawless, durable finishes, while production managers are under pressure to reduce cycle times, energy consumption and waste. This is where in-line systems make the difference. By integrating cleaning, UV coating, curing and sputtering metallization into a single continuous flow, they allow manufacturers to cut operational costs without sacrificing quality or flexibility.
Tapematic has built its technology around this principle, combining precision engineering, automation and modular design to create systems that deliver repeatable results with optimised use of resources. The result is a new way of thinking about cost efficiency in packaging decoration.
At the heart of this approach is the PST Line II, a fully in-line system designed to handle complex decoration processes with minimal manual intervention. Components are loaded onto standardized trays and then move through a sequence of dedicated modules: cleaning and pretreatment, UV coating, curing and, when required, sputtering metallization.
This architecture brings multiple cost advantages. First, it reduces handling and associated labour, as parts do not need to be transferred between separate machines or workstations. Second, it shortens production paths and limits downtime between processes. Every step is synchronized and controlled, which supports predictable throughput and fewer bottlenecks.
The modular design also helps optimize investment. Manufacturers can start with a configuration aligned to current volumes and applications, then add modules as demand grows or new decorative effects are required. This avoids over-dimensioned systems and spreads capital expenditure over time — a key factor in long-term operational cost control.
Material waste is one of the hidden costs in decoration. Overspray, inconsistent application and rework quickly erode margins. In an in-line system like PST Line II, UV coating is applied under tightly controlled conditions, with precise dosing, stable distances and repeatable movement profiles.
Automation ensures that each component receives the same treatment, cycle after cycle. This leads to several cost-saving effects. Less coating is wasted, fewer parts are rejected and there is less need for manual inspection or rework. The fast curing properties of UV coatings limit energy consumption, while the compact layout of the line reduces the footprint needed on the production floor.
Because all these parameters are managed by integrated control systems, recipes can be stored and recalled easily. This makes changeovers faster and more reliable, again reducing non-productive time and improving overall equipment effectiveness.
Equipped with dual independent cathodes, S8+4 can deposit distinct metal layers in a single continuous cycle. This allows manufacturers to create both decorative finishes and coatings that enhance mechanical resistance or functional properties, without adding separate process steps. A production capacity exceeding 10,000 parts per hour means that even high-volume orders can be processed on a single line.
From a cost perspective, this has multiple implications. The ability to combine layers in one cycle reduces overall processing time, lowers energy usage per part and simplifies logistics inside the plant. At the same time, the stability and uniformity of the sputtering process contribute to consistent quality, which translates into fewer rejects and less scrap.
Because S8+4 is compatible with the PST tray concept, it can be integrated directly into PST Line II or used as a stand-alone unit connected to existing coating lines. This flexibility makes it easier to upgrade current installations and enhance metallization capacity without building entirely new infrastructures.
Not every manufacturer requires a fully modular system. For situations where space and budget are more constrained, the PST Line C offers an alternative that retains many of the advantages of the PST Line II while simplifying the overall layout.
The PST Line C is a single, compact in-line installation with the same functional capabilities in terms of cleaning, UV coating, curing and decoration. It is not limited to cylindrical parts and can handle a broad range of shapes, making it suitable for different packaging geometries in cosmetics, beverage or other sectors.
By concentrating multiple processes into a single structure, PST Line C lowers installation and maintenance costs. It also reduces the number of interfaces and components that need to be managed on a daily basis. For many companies, this balance of performance, footprint and investment becomes a decisive factor in reducing operational expenses while still meeting demanding quality requirements.
In an in-line system, process stability leads to more predictable consumption profiles. Less waste means lower disposal costs and a more efficient use of raw materials. Automated handling reduces the risk of damage or contamination between stages, which further decreases the number of parts that need to be scrapped.
For manufacturers, this integrated approach creates a virtuous circle. By investing in in-line systems such as PST Line II, PST Line C and S8+4, they gain access to higher throughput, stable quality and greater decorative flexibility, while also cutting running costs and aligning with sustainability targets.
By combining modular in-line architecture, precise UV coating, high-speed sputtering metallization and intelligent automation, Tapematic provides a concrete answer to this challenge. In-line systems streamline workflows, reduce handling, minimise waste and optimise energy use, all while delivering the level of quality expected in premium markets.
In this way, advanced in-line technology becomes more than a production tool. It becomes a strategic lever, helping manufacturers transform cost structures, strengthen competitiveness and build a more sustainable model for decorative packaging, without ever compromising on excellence.
Tapematic has built its technology around this principle, combining precision engineering, automation and modular design to create systems that deliver repeatable results with optimised use of resources. The result is a new way of thinking about cost efficiency in packaging decoration.
PST Line II: a modular platform for efficient in-line production
At the heart of this approach is the PST Line II, a fully in-line system designed to handle complex decoration processes with minimal manual intervention. Components are loaded onto standardized trays and then move through a sequence of dedicated modules: cleaning and pretreatment, UV coating, curing and, when required, sputtering metallization.
This architecture brings multiple cost advantages. First, it reduces handling and associated labour, as parts do not need to be transferred between separate machines or workstations. Second, it shortens production paths and limits downtime between processes. Every step is synchronized and controlled, which supports predictable throughput and fewer bottlenecks.
The modular design also helps optimize investment. Manufacturers can start with a configuration aligned to current volumes and applications, then add modules as demand grows or new decorative effects are required. This avoids over-dimensioned systems and spreads capital expenditure over time — a key factor in long-term operational cost control.
Reducing waste with controlled UV coating and automation
Material waste is one of the hidden costs in decoration. Overspray, inconsistent application and rework quickly erode margins. In an in-line system like PST Line II, UV coating is applied under tightly controlled conditions, with precise dosing, stable distances and repeatable movement profiles.
Automation ensures that each component receives the same treatment, cycle after cycle. This leads to several cost-saving effects. Less coating is wasted, fewer parts are rejected and there is less need for manual inspection or rework. The fast curing properties of UV coatings limit energy consumption, while the compact layout of the line reduces the footprint needed on the production floor.
Because all these parameters are managed by integrated control systems, recipes can be stored and recalled easily. This makes changeovers faster and more reliable, again reducing non-productive time and improving overall equipment effectiveness.
High-speed metallization with S8+4: performance and flexibility in one system
When decorative or functional metallic effects are needed, sputtering metallization becomes a crucial step — and also a potential cost centre if not engineered correctly. The S8+4 module is designed to address this challenge by combining high-speed metallization with advanced process flexibility.Equipped with dual independent cathodes, S8+4 can deposit distinct metal layers in a single continuous cycle. This allows manufacturers to create both decorative finishes and coatings that enhance mechanical resistance or functional properties, without adding separate process steps. A production capacity exceeding 10,000 parts per hour means that even high-volume orders can be processed on a single line.
From a cost perspective, this has multiple implications. The ability to combine layers in one cycle reduces overall processing time, lowers energy usage per part and simplifies logistics inside the plant. At the same time, the stability and uniformity of the sputtering process contribute to consistent quality, which translates into fewer rejects and less scrap.
Because S8+4 is compatible with the PST tray concept, it can be integrated directly into PST Line II or used as a stand-alone unit connected to existing coating lines. This flexibility makes it easier to upgrade current installations and enhance metallization capacity without building entirely new infrastructures.
PST Line C: compact efficiency for cost-sensitive installations
Not every manufacturer requires a fully modular system. For situations where space and budget are more constrained, the PST Line C offers an alternative that retains many of the advantages of the PST Line II while simplifying the overall layout.
The PST Line C is a single, compact in-line installation with the same functional capabilities in terms of cleaning, UV coating, curing and decoration. It is not limited to cylindrical parts and can handle a broad range of shapes, making it suitable for different packaging geometries in cosmetics, beverage or other sectors.
By concentrating multiple processes into a single structure, PST Line C lowers installation and maintenance costs. It also reduces the number of interfaces and components that need to be managed on a daily basis. For many companies, this balance of performance, footprint and investment becomes a decisive factor in reducing operational expenses while still meeting demanding quality requirements.
Sustainability and operational savings: one integrated strategy
Modern decoration lines are evaluated not only by output and visual quality but also by their environmental impact. In practice, sustainability and cost efficiency often point in the same direction. The use of UV coatings, optimized vacuum management and automation all contribute to lower energy consumption and reduced material usage.In an in-line system, process stability leads to more predictable consumption profiles. Less waste means lower disposal costs and a more efficient use of raw materials. Automated handling reduces the risk of damage or contamination between stages, which further decreases the number of parts that need to be scrapped.
For manufacturers, this integrated approach creates a virtuous circle. By investing in in-line systems such as PST Line II, PST Line C and S8+4, they gain access to higher throughput, stable quality and greater decorative flexibility, while also cutting running costs and aligning with sustainability targets.
Balancing cost, quality and flexibility in packaging decoration
The challenge in packaging decoration has never been simply to reduce costs. The real goal is to lower operational expenses while preserving — and ideally improving — visual impact, functional performance and brand identity.By combining modular in-line architecture, precise UV coating, high-speed sputtering metallization and intelligent automation, Tapematic provides a concrete answer to this challenge. In-line systems streamline workflows, reduce handling, minimise waste and optimise energy use, all while delivering the level of quality expected in premium markets.
In this way, advanced in-line technology becomes more than a production tool. It becomes a strategic lever, helping manufacturers transform cost structures, strengthen competitiveness and build a more sustainable model for decorative packaging, without ever compromising on excellence.