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Multi-layer coatings in one pass with integrated PST Line
Discover how Tapematic’s integrated PST Line enables multi-layer coatings in a single pass, combining efficiency, quality, and reduced waste.
In industrial surface treatment, speed and precision are critical—but so is complexity. More and more manufacturers require multi-layer finishes that combine visual appeal, functional performance, and durability. Tapematic’s PST Line II offers a unique solution: the ability to apply multiple layers of coating—including UV primer, metallization, and UV topcoat—in a single, fully automated pass. This streamlined approach boosts productivity, improves coating consistency, and reduces material waste, all within a compact, modular design.
At the heart of Tapematic’s innovation is the PST Line II, a state-of-the-art, inline coating platform engineered to deliver multi-step surface treatments in one continuous flow. Developed for high-throughput applications, the system combines several integrated processes:
- Surface cleaning and pretreatment
- UV base coat application
- Vacuum metallization
- UV topcoat finishing
- Curing and part handling
Each of these steps is executed in sequence without the need to transfer parts between machines or interrupt production. The result is unmatched process efficiency and superior coating precision for industries such as cosmetics, pharmaceuticals, automotive, and beverage packaging.
Traditional coating lines often require multiple separate machines or manual handling between layers, increasing the risk of contamination, misalignment, or inconsistencies. Tapematic’s PST Line II eliminates these issues through a fully synchronized, single-pass process.
By integrating multiple stations in one machine, the PST Line II ensures:
- Consistent coating thickness across all layers
- Reduced cycle times
- Lower material and energy consumption
- Fewer defects and reworks
This level of integration is especially beneficial for packaging components that require reflective, decorative finishes—such as perfume caps, cosmetic jars, and dispensing closures—where multi-layer treatments are common.
A successful multi-layer process starts with a clean substrate. Tapematic addresses this with an integrated cleaning and pretreatment module, which removes contaminants and static charges before the first layer is applied.
Importantly, Tapematic does not use a traditional cleanroom setup. Instead, the PST Line II includes an internal, controlled environment that delivers similar performance standards without the space and maintenance requirements of a dedicated cleanroom. This design improves production flexibility while maintaining high-quality results.
A European cosmetics manufacturer recently implemented the PST Line II to streamline the production of high-gloss, mirror-finish caps for a new luxury skincare line. The desired finish required a UV primer, aluminum sputtering, and a clear protective topcoat.
With Tapematic’s technology:
- All three layers were applied in a single pass
- First-pass yield exceeded 95%
- Total production time was reduced by 40%
- Material waste dropped by 35% compared to the previous batch system
This allowed the company to shorten time-to-market while improving quality and reducing production costs.
For smaller production environments or companies looking for a non-modular solution, Tapematic offers the PST Line C. This system is built with the same advanced technology and supports the same multi-layer process as the PST Line II, but within a more compact and cost-effective footprint.
Despite being a single-unit machine, the PST Line C is capable of applying primer, metallization, and topcoat layers inline. It is not limited to cylindrical items and accommodates a wide range of component shapes and sizes.
One of the key technologies enabling single-pass multi-layer coating is UV spray coating. Used both for base and topcoats, UV coatings offer fast curing times and require no heat ovens, reducing energy consumption and operational costs.
Tapematic’s UV systems deliver:
- Instant curing under UV light
- High-performance finishes with excellent adhesion
- Reduced VOC emissions and improved workplace safety
- Minimal overspray and efficient material use
This approach is not only energy-efficient but also aligned with environmental regulations, helping manufacturers meet sustainability targets.
The metallization process, carried out via vacuum sputtering, is seamlessly integrated between the UV base and topcoat stages. Tapematic’s vacuum chambers are engineered to deliver uniform metal deposition even on complex 3D surfaces, creating reflective, durable finishes.
The controlled inline process ensures:
- Strong adhesion between coating layers
- Consistent metallic brightness and color
- Protection from oxidation or environmental degradation
- No interruption or repositioning between layers
This metallization is essential for creating luxury packaging finishes and technical coatings with functional benefits such as light-blocking or conductivity.
By aligning all steps of the multi-layer coating in one pass, the PST Line II significantly reduces the amount of coating material used. Intelligent controls monitor application parameters in real time, adjusting spray heads, conveyor speeds, and curing intensity to optimize consumption.
The result is:
- Lower total varnish usage per item
- Fewer rejects and less rework
- Cleaner work environment with minimal overspray
- Shorter cleaning and maintenance intervals
These efficiencies directly translate to cost savings and higher production sustainability.
Every function of the PST Line II is governed by a centralized control system with full automation. From part loading to final unloading, the system ensures precise timing and repeatable quality across production batches.
Features include:
- Touchscreen HMI with real-time process feedback
- Customizable process recipes
- Traceability and batch reporting
- Compatibility with Industry 4.0 and MES systems
This level of control is essential for high-volume production environments, where consistency, uptime, and process validation are key.
Tapematic’s integrated multi-layer coating technology represents a leap forward for manufacturers seeking speed, precision, and flexibility. The PST Line II and PST Line C provide complete solutions that reduce complexity, save resources, and deliver exceptional surface finishes in a single pass.
By combining engineering excellence with environmental responsibility, Tapematic helps its clients future-proof their coating operations across sectors that demand perfection - cosmetics, pharma, beverage, and automotive alike.
PST Line II: the backbone of single-pass multi-layer coating
At the heart of Tapematic’s innovation is the PST Line II, a state-of-the-art, inline coating platform engineered to deliver multi-step surface treatments in one continuous flow. Developed for high-throughput applications, the system combines several integrated processes:
- Surface cleaning and pretreatment
- UV base coat application
- Vacuum metallization
- UV topcoat finishing
- Curing and part handling
Each of these steps is executed in sequence without the need to transfer parts between machines or interrupt production. The result is unmatched process efficiency and superior coating precision for industries such as cosmetics, pharmaceuticals, automotive, and beverage packaging.
From primer to topcoat: all in a single run
Traditional coating lines often require multiple separate machines or manual handling between layers, increasing the risk of contamination, misalignment, or inconsistencies. Tapematic’s PST Line II eliminates these issues through a fully synchronized, single-pass process.
By integrating multiple stations in one machine, the PST Line II ensures:
- Consistent coating thickness across all layers
- Reduced cycle times
- Lower material and energy consumption
- Fewer defects and reworks
This level of integration is especially beneficial for packaging components that require reflective, decorative finishes—such as perfume caps, cosmetic jars, and dispensing closures—where multi-layer treatments are common.
Clean and ready: inline pretreatment without a cleanroom
A successful multi-layer process starts with a clean substrate. Tapematic addresses this with an integrated cleaning and pretreatment module, which removes contaminants and static charges before the first layer is applied.
Importantly, Tapematic does not use a traditional cleanroom setup. Instead, the PST Line II includes an internal, controlled environment that delivers similar performance standards without the space and maintenance requirements of a dedicated cleanroom. This design improves production flexibility while maintaining high-quality results.
Real use case: cosmetic packaging with high-gloss metallic finish
A European cosmetics manufacturer recently implemented the PST Line II to streamline the production of high-gloss, mirror-finish caps for a new luxury skincare line. The desired finish required a UV primer, aluminum sputtering, and a clear protective topcoat.
With Tapematic’s technology:
- All three layers were applied in a single pass
- First-pass yield exceeded 95%
- Total production time was reduced by 40%
- Material waste dropped by 35% compared to the previous batch system
This allowed the company to shorten time-to-market while improving quality and reducing production costs.
PST Line C: compact flexibility with multi-layer capability
For smaller production environments or companies looking for a non-modular solution, Tapematic offers the PST Line C. This system is built with the same advanced technology and supports the same multi-layer process as the PST Line II, but within a more compact and cost-effective footprint.
Despite being a single-unit machine, the PST Line C is capable of applying primer, metallization, and topcoat layers inline. It is not limited to cylindrical items and accommodates a wide range of component shapes and sizes.
UV coatings: fast curing and environmental benefits
One of the key technologies enabling single-pass multi-layer coating is UV spray coating. Used both for base and topcoats, UV coatings offer fast curing times and require no heat ovens, reducing energy consumption and operational costs.
Tapematic’s UV systems deliver:
- Instant curing under UV light
- High-performance finishes with excellent adhesion
- Reduced VOC emissions and improved workplace safety
- Minimal overspray and efficient material use
This approach is not only energy-efficient but also aligned with environmental regulations, helping manufacturers meet sustainability targets.
Precision metallization between UV layers
The metallization process, carried out via vacuum sputtering, is seamlessly integrated between the UV base and topcoat stages. Tapematic’s vacuum chambers are engineered to deliver uniform metal deposition even on complex 3D surfaces, creating reflective, durable finishes.
The controlled inline process ensures:
- Strong adhesion between coating layers
- Consistent metallic brightness and color
- Protection from oxidation or environmental degradation
- No interruption or repositioning between layers
This metallization is essential for creating luxury packaging finishes and technical coatings with functional benefits such as light-blocking or conductivity.
Material savings through synchronized application
By aligning all steps of the multi-layer coating in one pass, the PST Line II significantly reduces the amount of coating material used. Intelligent controls monitor application parameters in real time, adjusting spray heads, conveyor speeds, and curing intensity to optimize consumption.
The result is:
- Lower total varnish usage per item
- Fewer rejects and less rework
- Cleaner work environment with minimal overspray
- Shorter cleaning and maintenance intervals
These efficiencies directly translate to cost savings and higher production sustainability.
Full automation for reliable, repeatable results
Every function of the PST Line II is governed by a centralized control system with full automation. From part loading to final unloading, the system ensures precise timing and repeatable quality across production batches.
Features include:
- Touchscreen HMI with real-time process feedback
- Customizable process recipes
- Traceability and batch reporting
- Compatibility with Industry 4.0 and MES systems
This level of control is essential for high-volume production environments, where consistency, uptime, and process validation are key.
A complete solution for future-proof coating
Tapematic’s integrated multi-layer coating technology represents a leap forward for manufacturers seeking speed, precision, and flexibility. The PST Line II and PST Line C provide complete solutions that reduce complexity, save resources, and deliver exceptional surface finishes in a single pass.
By combining engineering excellence with environmental responsibility, Tapematic helps its clients future-proof their coating operations across sectors that demand perfection - cosmetics, pharma, beverage, and automotive alike.