In modern surface finishing and industrial metallization systems, manufacturers are expected to combine high output, repeatable quality and extreme customization within the same production environment. Traditional, monolithic equipment often struggles to keep pace with evolving product ranges, changing volumes and new decorative or functional requirements. This is where modular design becomes a decisive advantage.
By structuring in-line coating and 3D metallization equipment into independent yet interconnected modules, companies can configure and adapt their lines with far greater freedom. Solutions such as Tapematic PST Line II and the S8+4 in-line sputtering module are built around this philosophy, enabling manufacturers to scale capacity, introduce new processes and optimise layouts without redesigning their entire production infrastructure.

Modular architecture at the core of PSTLine II

At the heart of Tapematic’s approach is the PST Line II, a modular system specifically engineered for automated UV coating, sputtering metallization and in-line decoration. Instead of a single fixed machine, the line is composed of dedicated modules that can be arranged according to each customer’s needs.
Typical modules include:

• cleaning and pre-treatment units
• Primer coating system
• UV base coating systems
• in-line metallization modules such as S8+4
• UV Top  coating system
• inspection and handling units

Because each module has a defined function and standardized interfaces, manufacturers can tailor the line to their current portfolio while keeping open the possibility to expand or reconfigure later. This is a key differentiator compared to non-modular systems, where any change often requires extensive mechanical and control redesign.

Flexibility to serve multiple industries and products

Industrial metallization systems are used across diverse sectors, from cosmetic packaging and beverage closures to pharmaceutical components and automotive parts. Each of these markets has different geometries, materials, coating stacks and regulatory requirements. A modular design allows one line to address all of them more efficiently.
With Tapematic PST Line II, manufacturers can:

• start with a core configuration for a specific application
• add modules as new products or finishes are introduced
• integrate UV coating systems, additional curing stages or inspection units when required
• connect S8+4 as an in-line 3D metallization module for high-value parts

This means the same investment can support a broad product mix, instead of being locked into a narrow specification. As packaging designs become more sophisticated and differentiated, this flexibility translates into a significant competitive advantage.

The modular design of the s8+4 metallization module

The Tapematic S8+4 is a clear example of how modular design applies directly to in-line sputtering. It is engineered as a self-contained metallization module that fits seamlessly into the PST Line architecture or can operate as a standalone unit integrated with existing coating lines from different brands.
Key features that highlight its modular nature include:

• a dedicated dual sputtering system with dual-independent cathodes
• compatibility with PST Line trays and handling systems
• scalability for different capacity requirements
• easy integration into new or existing workflows

Because S8+4 is conceived as a module rather than an isolated machine, it can be positioned after UV coating systems, combined with specific pre-treatment stages or coupled with downstream inspection according to each application. This modularity gives manufacturers freedom to design the exact process sequence they need, without compromising stability or throughput.

Scaling capacity without redesigning the entire line

One of the most tangible benefits of modular industrial metallization systems is the ability to scale capacity progressively. Growing demand does not necessarily require a new line; instead, manufacturers can extend an existing one.
With PST Line II, this can mean:

• adding new UV coating stations to increase surface preparation capacity
• introducing an extra curing or cooling module to support thicker or more complex layer stacks
• installing an additional S8+4 module to boost 3D metallization throughput

Because the line is built around standardized mechanical and control interfaces, these upgrades are far simpler than redesigning a conventional system. The result is faster adaptation to market growth and seasonal peaks, with less disruption to ongoing production.

Optimising layouts and workflow efficiency

Factory layouts are rarely static. Floor space, logistics and upstream or downstream processes evolve over time. Modular design in industrial metallization systems allows manufacturers to adjust line layout while preserving process integrity.
Tapematic’s combination of tray handling systems and modular stations supports:

• linear or U-shaped line configurations
• space-optimised footprints in constrained environments
• separation of clean and non-clean areas when required
• clear segmentation between coating, in-line metallization and inspection

Because each module is defined in terms of function and footprint, engineers can reposition or re-balance stations without compromising performance. This layout flexibility is fundamental for plants that must integrate metallization within broader, multi-technology production flows.

Combining decorative and functional coatings with modularity

Modern surface finishing increasingly blends decorative metallization with functional coatings such as protective layers, conductive films or barrier structures. A modular system makes it easier to design process sequences that support this complexity.
For example, a line based on PST Line II and S8+4 can be configured to include:

• pre-treatment and UV coating for adhesion and surface preparation
• a first sputtering step with one of the dual-independent cathodes for decorative 3D metallization
• a second sputtering phase using the other cathode for mechanical or barrier performance
• an additional curing or top-coat module for final protection

Because each operation is hosted in its own module, modifying layer stacks or introducing new finishes can be done with minimal disruption. This modular approach supports faster development cycles and more agile responses to customer-specific requests.

Sustainability and resource optimisation through modular design

Sustainability is an integral part of modern industrial metallization systems. Modular design contributes directly to more responsible production by allowing manufacturers to configure lines with only the modules they truly need and to optimise energy usage across the workflow.
Tapematic’s approach brings several advantages:

• efficient use of power in in-line sputtering and UV curing
• reduced waste thanks to stable, repeatable processes
• the possibility to refine or upgrade individual modules without scrapping the entire line
• compact layouts that minimise unnecessary transport and handling

By integrating advanced automation, resource-conscious engineering and modular architecture, systems such as PST Line II and S8+4 help manufacturers align their decoration and metallization strategies with environmental and operational goals.

A strategic platform for future process evolution

Perhaps the most important impact of modular design in industrial metallization systems is strategic. Instead of investing in rigid, single-purpose equipment, manufacturers build a platform that can evolve with their business.
With Tapematic PST Line II, S8+4, UV coating systems, tray handling systems and advanced automation all conceived as interoperable modules, companies gain a long-term foundation that supports:

• rapid introduction of new finishes and products
• progressive capacity expansion
• integration of emerging technologies within the same architecture
• consistent quality across changing portfolios

In this way, modular design does more than simplify engineering. It transforms industrial metallization into a dynamic, adaptable asset that can follow market trends, brand strategies and technical innovations without requiring complete reinvestment every time requirements change.