In the world of packaging decoration, the visual impact of a product often hides a complex and demanding industrial process. Metallization and coating can be energy intensive and material heavy if they are not designed with efficiency in mind. At the same time, brands and manufacturers are under growing pressure to deliver premium finishes while reducing their environmental footprint.
This is where sustainable metallization becomes a strategic priority. Tapematic focuses on combining in-line automation, uv coating systems and advanced sputtering technologies to cut waste, lower energy consumption and increase process stability, without compromising on decorative or functional performance.

PST Line II as the backbone of sustainable production

The heart of Tapematic’s approach is the PST Line II, a highly automated modular in-line system designed to manage surface finishing in a single continuous flow. Parts are loaded onto standard trays and travel through the entire line without manual intervention.
By integrating cleaning, pre-treatment, uv coating, sputtering metallization and curing into one uninterrupted sequence, the PST Line II helps to:

• minimise unnecessary handling
• reduce the risk of damage and rework
• keep process parameters under tight control
• avoid idle times between separate machines

This optimisation of the production flow has a direct impact on sustainability. Fewer intermediate steps mean fewer chances for errors, fewer rejected parts and a more efficient use of both materials and energy.

How in-line automation reduces waste

Traditional metallization setups often rely on disconnected machines and manual transfers. Each step introduces potential misalignment, contamination or variability. Every rejected part represents wasted substrate, coating and energy.
With in-line automation, these inefficiencies are significantly reduced. In the PST Line II, trays move from station to station in a controlled and repeatable way. The same orientation, speed and positioning are maintained throughout the line. This stability improves:

• uniformity of uv coating thickness
• consistency of metal layer deposition
• accuracy of curing times

As a result, the number of parts that fail quality checks drops, and overall scrap levels are reduced. Less scrap means less raw material being processed for no result, which translates directly into lower environmental impact.

UV coating as a sustainable enabler

Tapematic systems make extensive use of uv coatings, which play a key role in sustainable metallization. Compared to traditional thermal curing methods, uv curing can be faster and more energy efficient, because energy is targeted precisely where and when it is needed.
The advantages of uv coating in a sustainable context include:

• rapid curing that shortens the time parts spend in the line
• lower overall energy requirements per coated piece
• thinner, well controlled film thickness that avoids over-application
• reduced emissions associated with the coating process

When uv technologies are combined with sputtering metallization in an in-line configuration, manufacturers gain a powerful tool to deliver high-end finishes with optimised resource use.

S8+4 dual sputtering module and sustainable design

The S8+4 dual sputtering module is a clear example of how advanced technology can support a more sustainable approach to metallization. Equipped with two fully independent cathodes, the S8+4 can deposit distinct metal layers in a single continuous cycle.
From a sustainability perspective, this brings several benefits:

• multiple layers are created in one pass, avoiding additional process steps
• less handling reduces the risk of damage and rework
• precise control of deposition parameters limits material overuse
• high throughput ensures that energy is spread efficiently over a large number of parts

By combining decorative and functional coatings in one operation, the S8+4 helps manufacturers achieve ambitious surface performance targets while keeping an eye on resource efficiency and energy use.

Energy optimisation through intelligent process control

Sustainable metallization is not only about the number of process steps. It also relies on how energy is managed within each machine and across the whole line. Tapematic focuses on optimised vacuum management, smart power distribution and advanced monitoring of process conditions.
By controlling the vacuum environment, the system can reach and maintain the necessary sputtering conditions using energy more efficiently. Smart power management ensures that cathodes and auxiliary components receive exactly the energy they need, avoiding waste and unnecessary peaks in consumption.
Because the entire PST Line II and modules such as S8+4 are designed to work together, data from each station can be used to fine tune the overall energy profile of the installation, supporting long term efficiency gains.

The tray concept and its impact on sustainability

The use of a standard tray concept across Tapematic lines may seem like a purely mechanical choice, but it has direct consequences for sustainability. Trays provide a stable and repeatable interface between parts and process modules.
This concept contributes to:

• fewer adjustments when switching between different products
• reduced mechanical complexity and maintenance
• lower risk of misalignment that can lead to defective parts
• smoother integration of new modules into existing lines

Because trays can handle a variety of shapes and sizes, manufacturers can adapt their production mix without needing entirely new handling systems. This reduces the demand for additional equipment and the resources associated with its production, installation and operation.

Compact and efficient solutions with PST Line C

For manufacturers that need a smaller footprint, PST Line C offers the same fundamental philosophy as PST Line II in a more compact, non modular layout. This unique system maintains the ability to perform coating and metallization on different geometries, not just cylindrical parts.
From a sustainability viewpoint, PST Line C delivers:

• high quality decoration in a space efficient configuration
• reduced infrastructure requirements
• integrated handling that lowers the need for external transport systems

This makes it an attractive option for companies that want to introduce sustainable metallization without restructuring entire facilities, or for those that wish to dedicate a specific line to eco-conscious decoration projects.

Aligning metallization with industry 5.0 principles

Sustainable manufacturing is closely linked to the concept of industry 5.0, where technology supports people and the environment at the same time. Tapematic systems are designed so that automation, robotics and smart control tools work alongside operators to create safer and more efficient workplaces.
In this context, sustainability is enhanced because:

• operators spend less time on repetitive, energy intensive tasks
• process data can be used to detect inefficiencies early
• predictive logic can prevent unplanned stops and resource heavy restarts
• quality issues are detected quickly, limiting the number of parts that must be scrapped

By combining human expertise with reliable automated systems, metallization lines become cleaner, more predictable and better aligned with long term environmental goals.

Sustainable metallization as a competitive advantage

For many organisations, sustainability is no longer only a matter of compliance, it is a market differentiator. Packaging that looks premium and is produced through sustainable metallization supports brand positioning and corporate responsibility objectives at the same time. Tapematic solutions, including PST Line II, PST Line C and the S8+4 dual sputtering module, demonstrate how waste reduction, energy optimisation and high quality surface finishing can coexist within a single integrated architecture. By reducing rejects, lowering energy consumption, optimising uv coating and introducing intelligent in-line processes, Tapematic helps manufacturers transform metallization from a resource intensive operation into an efficient, forward looking part of modern packaging production.