Sol-Gel Non-Stick Coatings for Packaging Equipment
Improving heat-sealing reliability, product flow and equipment life using Sol-Gel Non-Stick Coatings
A Harder, Cleaner-Running Surface for Demanding Packaging Lines
Packaging machinery is exposed to repeated heating cycles, abrasive materials, food products, adhesives and frequent cleaning. Marcote's Sol-Gel coatings provide a hard, abrasion-resistant and non-stick surface designed to help components stay cleaner, perform more consistently and last longer.
They can also provide a practical route for manufacturers looking to reduce intentionally added PFAS while maintaining strong engineering performance.
Speak to Our Technical TeamSticking, Build-Up and Wear Were Disrupting Production
A food-packaging manufacturer was experiencing performance losses in two areas of its packaging line: heat sealing and multihead weighing.
Heat Seal Bars
Packaging film and product contamination were building up on the sealing surfaces, affecting heat transfer and release.
- Inconsistent or incomplete seals
- Film sticking to the sealing face
- Torn or distorted packs
- Frequent cleaning stops
- Premature wear from scraping and abrasive cleaning
- Regular refurbishment or replacement
Multihead Weighing Equipment
Sticky, oily and lightly seasoned products were adhering to feed trays, weigh hoppers and discharge chutes.
- Incomplete product discharge
- Inconsistent pack weights
- Increased product giveaway
- Reduced machine speed
- Longer cleaning and changeovers
- Manual operator intervention
Improve Release Without Sacrificing Durability
The coating system needed to deliver dependable release while withstanding repeated contact, elevated temperature, thermal cycling, cleaning and normal production wear.
Release Performance
Reduce film, adhesive and product adhesion.
Surface Hardness
Improve resistance to scratching and abrasive cleaning.
Temperature Capability
Remain stable through repeated heat cycles and thermal spikes.
Cleaning Efficiency
Reduce aggressive mechanical cleaning and downtime.
Component Life
Extend intervals between refurbishment and replacement.
Material Strategy
Support customers seeking PFAS-free coating options where appropriate.
A Controlled Sol-Gel Coating Process
Marcote reviewed the substrates, operating temperatures, cleaning methods and products being processed before selecting the appropriate Sol-Gel system.
Component Inspection
Confirm the condition of each part and its suitability for coating.
Degreasing & Cleaning
Remove oils, processing contamination and residues from the surface.
Abrasive Preparation
Prepare the substrate to create the correct surface profile for coating adhesion.
Professional Spray Application
Apply the selected Sol-Gel coating system under controlled conditions.
Thermal Cure
Cure the coating according to the selected system and substrate requirements.
Final Inspection
Inspect coverage, finish and coating integrity before release.
Cleaner Release, More Stable Processing, Less Intervention
Cleaner release of packaging film from heat seal bars
More consistent heat transfer across sealing surfaces
Reduced sticking, bridging and product accumulation
Shorter cleaning and changeover periods
Reduced reliance on scraping and abrasive cleaning tools
Longer intervals between refurbishment or replacement
Where Sol-Gel Coatings Can Support Packaging Equipment
Heat Seal Bars
Hard, heat-resistant release surfaces for sealing applications.
Sealing Plates
Improved resistance to contamination and abrasive cleaning.
Multihead Weighers
Reduce sticking across trays, hoppers and chutes.
Guide Rails
Low-friction surfaces for smoother product or pack transfer.
Idler Rollers
Improved release and resistance to packaging residue.
Folding & Forming Parts
Durable surfaces for repeated contact with packaging materials.
What Better Release and Durability Can Mean Commercially
The figures below are representative scenarios based on the operating assumptions supplied for this case study. Actual savings will vary by product, equipment design, production speed and cleaning regime.
Heat Seal Bars
Multihead Weighers
A Strong Fit for High-Wear, High-Temperature Packaging Components
High Abrasion Resistance
A hard, ceramic-like surface helps resist scratching, wear and repeated contact.
Good Non-Stick Performance
Lower surface energy helps packaging film, adhesives and food products release more easily.
High-Temperature Capability
Selected systems can provide continuous service around 280–300°C, depending on formulation, substrate and operating conditions.
Reduced Cleaning
Less build-up can reduce cleaning time and the need for aggressive mechanical action.
Longer Component Life
Reduced contamination, scratching and abrasive cleaning can extend service intervals.
PFAS-Free Options
Sol-Gel systems can be formulated without intentionally added PFAS, supporting evolving customer and material strategies.
Explore PFAS-Free Coatings for Industrial Applications→Sol-Gel Compared With Fluoropolymer Coatings
Sol-Gel does not automatically replace PTFE, PFA or FEP in every application. The correct coating depends on how the component operates and which performance characteristics matter most.
| Performance requirement | Sol-Gel | PTFE, PFA & FEP |
|---|---|---|
| Initial non-stick performance | Good to very good | Generally excellent |
| Hardness & scratch resistance | Excellent | Moderate |
| Abrasion resistance | Excellent | Depends on grade and reinforcement |
| High-temperature stability | Excellent for selected systems | Good, but normally lower practical service limits |
| Aggressive chemical resistance | Good, formulation dependent | PFA and FEP generally superior |
| Flexibility & impact tolerance | More rigid and ceramic-like | Generally more flexible |
| PFAS-free availability | Yes, depending on selected system | No |
| Best suited to | High-wear and high-temperature components | Maximum release and aggressive chemical exposure |
Where maximum non-stick performance or exceptional chemical resistance is required, a fluoropolymer may still provide the best solution. Where abrasion resistance, hardness, higher temperature performance and PFAS considerations are the priority, Sol-Gel can offer a significant advantage.
Choose the Coating Route That Fits the Application
Fluoropolymer Coatings
Explore Marcote's PTFE, PFA and FEP coating capabilities for applications where maximum release or chemical resistance remains the priority.
View Fluoropolymer Coatings →PFAS & Coating Guidance
Read Marcote's guidance on the changing PFAS landscape, coating selection and when alternative technologies should be considered.
Read the PFAS Guidance →Sticking, Build-Up or Component Wear Affecting Your Packaging Line?
Marcote can assess your existing parts, operating conditions and coating requirements, then recommend the most appropriate Sol-Gel or fluoropolymer system. Existing components can often be stripped, prepared and recoated as a cost-effective alternative to replacement.
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