Transfer metallization for sustainable high-barrier papers

Product protection for demanding applications

Sensitive food and pharmaceutical products require packaging with a high barrier against oxygen and water vapor. At the same time, demand is increasing for recyclable solutions that use as little material as possible. Paper provides an attractive base material, but without additional barrier layers it often cannot deliver the level of product protection required.

In the international research project "IMPACT", Fraunhofer IVV, together with partners from Germany and Brazil, is developing the scientific foundations for a new generation of recyclable high-barrier papers. The project partners combine their expertise in packaging materials, material characterization, process development, and mathematical modeling. The goal is to further develop transfer metallization technology into a robust process suitable for industrial implementation.

High barrier performance with high fiber content

"IMPACT" builds on the results of the "TransMet" research project. That project already demonstrated that high-performance barrier layers can be transferred onto paper and that barrier properties suitable for numerous food and pharmaceutical packaging applications can be achieved.

In transfer metallization, ultra-thin functional barrier layers in the nanometer range are first deposited onto a carrier film and subsequently transferred to the paper substrate. This approach enables the high barrier performance of modern vacuum coatings to be utilized without significantly compromising the material’s recyclability. As a result, packaging materials with a very high fiber content can be produced.

The technology therefore combines two requirements that have often been considered conflicting objectives: reliable product protection and a predominantly fiber-based, recyclable packaging concept.

Within the project, we investigate how paper quality, surface properties, adhesive systems, and process parameters influence the transfer process. The aim is to identify the key influencing factors and derive robust processing windows for different material systems.

Industrial feasibility

The insights gained in the project are being validated under conditions close to industrial practice. Several thousand linear meters of high-barrier paper provide the basis for further developing and scaling the process, as well as assessing its applicability to a wide range of packaging applications.

A key advantage for companies is that the transfer process can be integrated into existing converting and finishing lines. This allows manufacturers to avoid major investments in new production facilities.

Interested in transfer metallization for your packaging development? Learn more about our services and opportunities for collaboration.