In order to create our metallized papers, we use a machine called a metallizer - basically a giant vacuum chamber in which papers are vaporized with a microscopically-thin layer of aluminium, giving them their signature glossy look and functional properties.

Here’s how a metallizer works:

Once a paper roll has been precoated and loaded into the machine, its full width is covered with “wires” of 99.99% pure aluminium. 

Air and vapours are then pumped out of the vacuum chamber to lower the internal pressure and seal it tight. This is done in 3 stages:

1. Most of the air volume is removed using roughing pumps
2. Further air and vapours are removed with booster pumps
3. Diffusion pumps, which are highly specialized and have no moving mechanical parts, “trap” and remove the final few molecules as they bounce around in a near-vacuum. These pumps take the metallizing zone from low to very low pressure.

Once the pressure is around 1000 times lower than that of the atmosphere, the paper is fed through the machine and unwound from the rolls. The aluminium wires are simultaneously melted and vaporised onto the paper, while a chilled roller prevents the paper from heating and condenses the aluminium vapour onto the surface. Controlling heat and vacuum levels and paper and wire speed enables the application of a continuous, bright silver coating with the necessary thickness and appearance.