Fda-compliant DLC coating for improved product evacuation in packaging

Overview

This solution offers an FDA-compliant diamond-like carbon (DLC) inner-surface coating applied via roll-to-roll plasma deposition on packaging materials. The ultrathin amorphous carbon layer significantly reduces adhesion and wall friction, allowing near-complete evacuation of viscous products like toothpaste and creams. This not only minimizes consumer frustration but also supports sustainability by enhancing recyclability. The DLC coating is chemically inert, transparent, and thermally stable, making it ideal for maintaining seal integrity at high temperatures.

Technical specifications

Key features:

• Ultrathin Coating: 10-50 nm DLC layer that is invisible and adds negligible weight.
• Compatibility: Suitable for HDPE mono-material and HDPE+EVOH structures.
• Thermal Stability: Tolerates sealing temperatures up to ~250 °C.
• Scalability: Supports high-throughput manufacturing processes.
• Inertness: Chemically inert and food-contact approved, ensuring product safety.

Applications:

• Viscous product evacuation from tubes and bottles, such as toothpaste, creams, and gels.
• Can be integrated into existing packaging lines without altering design or process conditions.

Technology readiness level

This technology is at TRL 6, having been validated in a relevant environment with further optimization and pilot testing planned. The path to commercialization includes further phases focusing on safety, compliance, and scale-up.