A new plasma-enhanced coating/ vapor-deposition (PECVD) process, called PlasmaStar, is claimed to be a low-cost barrier solution for PET and PP bottles.

A new plasma-enhanced coating/ vapor-deposition (PECVD) process, called PlasmaStar, is claimed to be a low-cost barrier solution for PET and PP bottles. Developed by Nano Coating Systems LLC of Fremont, Calif., the system applies a silicon oxide coating only 15 nanometers thick inside a blow molded bottle at a cost of less than $6/1000 bottles. The new process, which uses radio-frequency energy to generate the plasma, costs less than a competitive PECVD system that uses microwave energy, according to William Liggett, Nano Coating's president and CEO. The machine also has a smaller footprint than competitive models. The company has done extensive work with PET bottles and over the last six months has worked with Dow Chemical, Midland, Mich., on barrier coating of PP. Testing has revealed that coated 500-cc PET bottles have 4.5 times greater CO2 barrier than uncoated PET. Similarly, the oxygen transmission rate for hot-fill PP bottles is 95% less for than uncoated PP. The coating system has passed regulatory testing and meets requirements for abuse resistance, micro-filtration, and taste, says Liggett. Husky Injection Molding Systems, Bolton, Ont., will handle distribution, service, and spare parts for the coating machinery. It is a stand-alone unit but can be integrated with a conveyor for in-line blow molding and coating. A prototype unit has capacity for 10,000 bottles/hr. The first commercial machine, slated to ship in the third quarter, will coat 20,000 bottles/hr. Husky: (905) 951-5000/PTDirect: 946LF . Nano Coating: (510) 249-9601/www.ns3inc.com

Husky Injection Molding
Systems
500 Queen St. South Bolton L7E 5S5, Ontario, Canada
Phone (905) 951-5000 Fax