Performance & Durability in Laminated Packaging
Extrusion Coating
Extrusion coating has become a critical conversion technology in the flexible packaging, industrial coverings, paper–plastic laminates, and barrier-sensitive markets. With increasing sustainability demands, lightweighting goals, and performance-driven packaging standards, advanced masterbatch formulations play a pivotal role in elevating coating quality, surface functionalities, and process efficiency.
This article offers a complete technical overview of extrusion coating applications, the importance of masterbatches, and the specialized formulations required for high-performance results.
What is Extrusion Coating?
Extrusion coating is a continuous lamination process where a molten thermoplastic polymer—typically LDPE, LLDPE, HDPE, PP—is extruded as a thin, uniform layer onto a substrate such as:
Paper & kraft paper
Woven & nonwoven fabrics
Aluminium foil
BOPP films
Multilayer barrier substrates
The coated structure provides enhanced barrier, sealability, chemical resistance, waterproofing, abrasion protection, and improved surface aesthetics.
How Extrusion Coating Is Done (Process Overview)
Extrusion-coated laminates are widely used across multiple B2B sectors:
Industry | Application | Functional Advantages |
|---|---|---|
Flexible Packaging | Milk, edible oil, food-grade pouches | Sealability, hygiene, moisture barrier |
Industrial Fabrics | FIBC liners, geotextile coating | Protection & UV durability |
Paper Packaging | Cup stock, PE-coated paper bags | Liquid barrier & heat seal |
Pharma & Medical | Sterilization packaging | Contamination resistance |
Aluminum Lamination | High-barrier food packaging | Aroma retention, oxygen barrier |
Importance of Extrusion Coating in the Current Packaging Market
Ensures leak-proof packaging performance
Enables recyclable mono-material solutions
Reduces the need for heavy barrier substrates → cost & weight optimization
Plays a vital role in food safety compliance
Essential for brand protection & print finish improvement
Expanding demand in e-commerce & sustainable packaging sectors
Extrusion coating market growth is driven by increasing consumption in FMCG, agro-textiles, industrial covers, and hygiene sectors.
Our Masterbatch Portfolio for Extrusion Coating
We offer advanced masterbatches engineered for extrusion coating lines operating at high speeds and temperatures:
1. Bajaj Plast White Masterbatch (TiO₂ Based)
High opacity & superior coverage
Food-contact & migration-safe grades
Excellent process stability at high draw ratios
2. Bajaj Plast Color Masterbatch
Color-fast, non-bleeding pigments
Suitable for brand identity laminates
3. Bajaj Plast UV Stabilizer Masterbatchh
Protects coatings against outdoor degradation
Ideal for geotextiles, agro-coated fabrics & industrial tarpaulins
4. Bajaj Plast Slip & Anti-Block Masterbatch
Controls COF in lamination & winding operations
Reduces blocking during storage stacking
5. Bajaj Plast Anti-Oxidant / Processing Stabilizers
Prevents polymer scorching & thermal oxidation
Improves extrusion line productivity
6. Bajaj Plast Desiccant Masterbatch
Eliminates moisture-caused bubbles, pinholes & gel defects during coating
How Extrusion Coating Is Done (Process Overview)
1.Polymer + Masterbatch Feeding
Resin mixed with masterbatch additives using gravimetric dosing or volumetric feeders.
2.Extrusion Through T-Die
Polymer is melted at 280–320°C (depending on polymer type).
3.Substrate Bonding
Molten layer is pressed onto substrate via chill rolls under controlled nip pressure.
4. Cooling & Winding
Structure solidifies, ensuring strong adhesion and surface properties.
Critical parameters: MFI (melt flow index), COF (coefficient of friction), anti-blocking level, oxidation stability, surface wetting.
Why Masterbatches Are Critical in Extrusion Coating
Masterbatches impart essential functional, optical and processing enhancements including:
Uniform whiteness, opacity & color identity
UV stabilization for outdoor usage
Anti-block and slip properties for improved handling
Anti-oxidation to prevent thermal degradation
Better adhesion and printability
Moisture & contamination control
Without optimized masterbatch formulations:
Surfaces become sticky or hazy
Film gauge variation increases
Polymer degradation causes gel & black spot defects
Shelf life of laminates reduces significantly
Sub-Applications Where Our Masterbatches Excel
PE extrusion coating on paper for cups, paper bags & FMCG packaging
Extrusion coating for woven PP fabric (FIBC & tarpaulin)
Liners for agro-products, fertilizers & chemical sacks
Hot-melt adhesive tie layers
Alu-foil lamination for high-value food packaging
Why Choose Our Masterbatches for Extrusion Coating?
✔ Designed for high-temperature and high-line-speed operations
✔ Zero fish-eye, low gels & excellent thermal stability
✔ Strong extrusion bonding for wrinkle-free coatings
✔ Consistent opacity & COF tuning for converting ease
✔ Custom R&D for specific polymer grades & substrates
✔ Regulatory-compliant for food-grade and export markets
Conclusion
Extrusion coating continues to evolve as a core enabler of premium, high-performance packaging. The right selection of masterbatch solutions ensures:
Enhanced mechanical and optical properties
Defect-free lamination performance
Lower operational costs and improved output efficiency
Longer product life cycles and market competitiveness
We provide application-matched masterbatch formulations tailored for modern extrusion coating requirements — ensuring that your final product exceeds performance expectations in every layer.
About Bajaj Plast Pvt. Ltd.
Bajaj Plast Pvt. Ltd. is a leading manufacturer of high-quality masterbatch solutions, dedicated to innovation, sustainability, and excellence. With a strong focus on customer satisfaction and cutting-edge technology, we are committed to delivering superior products that meet the evolving needs of the polymer industry.
