The new automated BOBST EXPERT K5 is leading innovation in metallization for high-quality film production with integrated process expertise powered by AI. By leveraging BOBST iMA technology for intelligent operator support, the metallizer directly addresses challenges in the flexible packaging sector while guaranteeing improved productivity, consistency and quality.

With a market share of 70%, BOBST metallizers can be found in film making plants and flexible packaging sites across the world. As an innovator in vacuum coating and metallizing, the company continues to advance its solutions to meet customer demands and tackle industry-wide challenges such as skills shortages, cost pressures and environmental concerns.

BOBST EXPERT K5: the next level in vacuum metallization

The next generation of the BOBST EXPERT K5 elevates vacuum metallizing by automating previously labor-intensive processes using AI. Employing BOBST’s unique iMA (Intelligent Metallizing Assistant) technology, the K5 offers automated and simplified operation less reliant on operator skills, resulting in faster setup and changeovers, and repeatable high quality with less waste. In addition, this new iteration increases sustainability by requiring less power to run and through savings on consumables. 

“The metallizing industry struggles to find skilled staff. These are complicated processes, and it takes a long time to train new operators – then retention can be difficult. Operator turnover and limited expertise cause quality issues and higher waste, especially when running new challenging materials or complex processes,” commented Richard Sandbrook, Product Line Director, Vacuum Metallizing. “With the next generation EXPERT K5, BOBST is advancing this powerful technology by increasing automation for even better productivity and consistent quality.”

Redefining efficiency with intelligent support for operators

Building on this strong foundation, BOBST has reimagined vacuum metallizing. The new EXPERT K5 is not just faster and easier to run, it represents a step change in how metallizing lines are operated, maintained and optimized. By embedding artificial intelligence and connected systems, BOBST is introducing autonomous machine operation that maximizes productivity and sustainability.

At the heart of this transformation is BOBST iMA, the first and only full-width control system on the market. The system replaces manual observation of the aluminum pool with high-definition cameras, allowing each evaporator to be viewed on a dedicated screen. Automated and simultaneous temperature control of up to 50 evaporators removes the need for constant manual adjustments, simplifying training and reducing setup times. The result is faster, more accurate and more consistent metallization, all monitored through the new Operator Console which consolidates every function in one place.

The smart design of the new EXPERT K5 also enables remote viewing and operation from anywhere, supported by BOBST Connect. This global connectivity makes remote support and assistance even more powerful and direct, ensuring uptime and operational continuity.

Equipped to tackle market challenges with ease

For converters, the impact is immediate and measurable. The new EXPERT K5 simplifies operation through easier viewing, setup and training, minimizing the dependency on skilled operators. Automation removes human variability, cutting large defects by 50% and reducing optimization length from 12.5km to just 5km per roll, saving on substrate costs and reducing waste. Crucially, there is full traceability, allowing rejected jobs to be tracked back to the root cause. A new, more evolved and faster vacuum pumping system further reduces changeover times, while advanced condition monitoring ensures maintenance is only performed when required, minimizing downtime and cutting costs.  At the same time, power consumption has been reduced by optimizing evaporator temperature, while lower consumable costs are guaranteed through increased evaporator life.

Ready to handle the next generation of packaging materials

The EXPERT K5 platform is also engineered for versatility and sustainability. It can handle a wide range of substrates, including BOPE, MDO PE, CPP, paper, and low-temperature, heat-sealable BOPP films, across widths from 1350 to 4850mm. A new option is the ability to run ultra-thin gauge films, such as 6-micron BOPP for lamination to paper. This makes it particularly relevant in today’s packaging landscape where thinner materials are preferred, driven by sustainability needs and demands. Meanwhile, BOBST’s AluBond® process for advanced metal adhesion and barrier levels is now standard, eliminating the need for chemically treated films, while optional AlOx GEN II technology adds high-barrier, transparent BOPP film production.

Commenting on this breakthrough, Davide Garavaglia, General Manager and Head of Product Lines Gravure, Vacuum, Coating & Laminating, said: “The EXPERT K5 is the perfect example of how BOBST’s vision – based on automation, digitalization, sustainability and connectivity – can transform the packaging industry. With this innovation, converters can achieve new levels of quality and productivity with less waste and complexity.

“This is the first metallizer on the market to feature such advanced automation, operating largely autonomously without the need for skilled operators. No other solution offers this level of intelligence and independence. As such, the launch is a true turning point for the flexible packaging sector – decoupling human expertise from product quality by ensuring exceptional, repeatable coating performance and yield.”