In markets such as cosmetics, automotive, beverage and pharmaceuticals, packaging components are expected to do much more than simply protect a product. They must look premium, perform reliably and be produced in a way that is both efficient and sustainable. To achieve this balance, manufacturers are increasingly relying on integrated surface treatment lines that combine flame treatment, plasma technologies, PVD and sputtering in a single, controlled process. Tapematic has built its approach around this idea, designing highly automated systems that transform decoration and metallization into a stable, repeatable and cost-effective workflow.

PST Line II as the backbone of integrated processes

The core of this architecture is PST Line II, a modular in-line system created to manage every step of the coating and metallization process in sequence. Components are handled on standardized trays and moved automatically through cleaning, pre-treatment, coating, curing and high-vacuum metallization. This tray concept reduces manual handling, limits the risk of damage and keeps each part positioned consistently from the first to the last station.
While PST Line I was the first system developed and remains an important milestone in the company’s history, PST Line II is now the reference platform and the real core business. For manufacturers who need similar capabilities in a more compact layout, PST Line C offers the same functional logic as PST Line II but in a single, non-modular machine, ideal when floor space and investment need to be optimized. In all cases, Tapematic integrates a dedicated cleaning and pre-treatment module, allowing customers to adapt the installation to their own factory layout.

Flame treatment as the first step for reliable adhesion

Before any PVD or sputtering process can deliver high-quality results, the substrate surface must be prepared correctly. This is where flame spray plays a vital role. During flame treatment, the surface is exposed to controlled flames that remove contaminants, lightly micro-roughen the material and increase its surface energy. For many plastics commonly used in cosmetic packaging, closures and technical parts, this step makes the difference between coatings that adhere firmly and coatings that may peel or lose performance over time.
On integrated lines such as PST Line II, flame treatment is positioned after mechanical cleaning and before the primer coating or base coating and metallization phase. This positioning ensures that each part enters the subsequent stations with a stable, activated surface. As a result, primers, UV coatings and metal layers bond more effectively, improving resistance to abrasion, chemicals and handling throughout the product’s life.

Plasma technologies to fine-tune surface performance

Alongside flame treatment, plasma technologies offer an additional level of control over surface properties. Plasma treatment uses ionized gases to modify the very top layer of the substrate, tailoring surface energy and improving wettability without altering the bulk material. When integrated into an automated line, plasma modules can be placed before a functional coating, between different layers or as a final activation step before top coating.
This flexibility is particularly valuable when working with complex shapes, mixed materials or demanding performance targets. For example, high-gloss decorative caps, automotive interior components and luxury packaging items may all require different combinations of flame and plasma treatment to ensure consistent appearance, sharp edges and durable finishes.

Combining PVD and sputtering for decorative and functional layers

Once the surface has been prepared with flame treatment, the component is ready for PVD and sputtering processes. Sputtering makes it possible to deposit metal layers with exceptional uniformity, even on three-dimensional geometries. By adjusting targets, power settings and process parameters, manufacturers can achieve a wide spectrum of effects, from bright metallic finishes to more technical coatings that enhance barrier properties or mechanical resistance.
In an integrated Tapematic line, these high-vacuum processes are combined with in-line spray coating and UV curing. A typical sequence may include a primer coat, a base coat, a sputtered metal layer and a protective top coat, all handled automatically on the same trays. This approach reduces cycle times, minimizes handling risks and ensures that each layer is applied under optimized conditions, which is essential for high-value sectors such as cosmetic, automotive and pharmaceutical components.

System-level benefits of an integrated approach

The real strength of combining flame treatment  and sputtering lies in the way these technologies are orchestrated at system level. Automation and robotics take care of repeatable movements, loading and unloading operations, and process timing, while advanced control software monitors key parameters such as line speed, temperatures, vacuum levels and curing conditions. This integration significantly reduces variability and helps keep scrap rates under control, even at high production volumes.
At the same time, optimized use of coatings, efficient curing and well-tuned metallization cycles contribute to more sustainable production. Material waste is reduced, energy consumption can be better managed and the overall process becomes more cost-efficient. For manufacturers, this means being able to offer sophisticated decorative and functional finishes while maintaining competitive operational costs and meeting increasingly strict environmental expectations.
By treating flame treatment  and sputtering spray, as interconnected tools rather than isolated steps, Tapematic enables a new level of control over both appearance and performance. The outcome is packaging and components that meet premium aesthetic standards, deliver long-term reliability and are produced on lines designed for the next generation of industrial manufacturing.