Extrusion Coating & Lamination Pilot Line: Building Functional Layers and Laminates
An extrusion coating pilot line applies a thin, molten layer of polymer onto a substrate such
as paper, film, or foil to add key functionalities including heat sealability, moisture resistance, and improved mechanical strength. When used in lamination mode, the same line bonds two different substrates together using the molten polymer as the tie layer - creating multilayer structures with the possibility to introduce a barrier functionality when needed.
For converters, the benefit is flexibility. Our pilot line in Cologne allows the development, testing, and optimisation of new packaging structures - especially recyclable mono PE or mono PP laminates - before scaling to full production. It supports customer trials, rapid prototyping, and the ability to refine coating weights, temperatures, and layer configurations with minimal material waste.
Coextrusion and MDO: Creating High-Performance Monomaterial Films
In 2024, INEOS became the world’s first polymer producer to commission a coextrusion blown film line coupled with in-line Machine Direction Orientation capability. Our pilot line in Brussels produces monomaterial films made from multiple layers, enabling strength, sealability, and barrier performance without introducing incompatible materials. When coextrusion is combined with Machine Direction Orientation, the film is directly stretched under controlled heat to significantly improve stiffness, clarity, toughness, and barrier properties.
For converters, the result is a recyclable film that can replace traditional PET or PA-based laminates. MDO is also valuable for downgauging and material savings, while the coextruded structure creates synergies in properties and delivers the performance needed for demanding applications such as pouches, flow wraps, and lidding films.
A Powerful Combination for the Circular Economy
Together, these two capabilities form a complete platform for developing the next generation of recyclable packaging. We offer converters the ability to:
- create high performance monomaterial films
- enhance stiffness, clarity, and barrier without PET lamination
- apply functional coatings and build laminates without adhesives
- rapidly prototype and test new structures
- meet brand and regulatory design for recycling requirements
This unique combination of development tools helps converters to stay competitive by offering lighter, simpler, and more sustainable flexible packaging that performs as well as, or better than, traditional multimaterial structures.
