In the world of advanced materials, few innovations have reshaped industrial and commercial processes as profoundly as adhesive & silicone-coated polyester films. These dual-coated PET films combine bonding strength on one side with controlled release on the other, creating a versatile base material for everything from industrial labels and medical tapes to graphic overlays and electronic components.
At Pilcher Hamilton Company (PHC) — based at 850 South Buncombe Road, Greer, South Carolina — our focus has always been on evolving with technology and industry needs. By combining adhesive and silicone technologies on a single polyester substrate, we deliver films that simplify processes, reduce waste, and enhance performance across a wide spectrum of applications.
If you’ve ever searched for “polyester near me”, you’ll likely come across PHC’s name — a century-old converter and supplier renowned for innovation, precision, and local service.
This article explores how these dual-coated PET films are made, their unique advantages, where they’re used, and how partnering locally with PHC USA ensures reliability, customization, and fast turnaround times.
How Dual-Coated PET Films Are Manufactured
Creating adhesive & silicone-coated polyester films requires precise control over surface chemistry, coating uniformity, and curing conditions. The goal is to produce a film that offers permanent adhesion on one side and clean release on the other, without cross-contamination or interference between coatings.
1. The Base: High-Quality PET Film
The process begins with a biaxially oriented polyester film (BOPET) — known for its dimensional stability, clarity, tensile strength, and thermal resistance. This base film provides the structural integrity needed for coating and converting operations.
Depending on the application, PHC can supply various base types, including:
- Clear or hazy PET
- Heat-stabilized PET
- Metallized PET
- Corona or chemically treated PET
- PVDC or acrylic-coated PET for enhanced surface performance
These base layers are meticulously selected for thickness, optical properties, and mechanical performance, ensuring compatibility with both adhesive and silicone coatings.
2. Surface Preparation
Before coating, the polyester surface is treated (usually by corona, flame, or plasma treatment) to enhance surface energy. This step improves coating adhesion and consistency, ensuring the silicone and adhesive layers anchor firmly to their respective sides.
3. Silicone Coating
One side of the PET is coated with a silicone release formulation, typically based on platinum-catalyzed or solventless silicone systems. This layer provides a smooth, non-stick surface that enables controlled release from adhesives, composites, and laminates.
PHC engineers carefully tailor the silicone chemistry to balance:
- Release force (light, medium, or tight release)
- Thermal resistance
- Cure profile
- Compatibility with pressure-sensitive adhesives (PSAs)
4. Adhesive Coating
The opposite side of the film receives an adhesive coating — such as acrylic, rubber-based, or silicone adhesives — designed for strong, lasting bonds to a range of substrates including paper, film, fabric, and metal.
This layer can be:
- Permanent (for industrial laminations)
- Removable or repositionable (for graphics and labeling)
- Pressure-sensitive (for tapes and transfer films)
5. Precision Curing and Winding
After coating, each layer is cured under controlled temperature and humidity, ensuring complete cross-linking and film stability. The dual-coated film is then slit, wound, and inspected for uniformity, thickness, and surface integrity.
PHC’s slitting and winding capabilities allow customization in width, roll size, and liner format — ready for downstream die-cutting, printing, or lamination.
Benefits: Bonding Strength Meets Smooth Release
Combining adhesive bonding and silicone release in one material unlocks unmatched versatility and process efficiency. These films serve as both the functional layer and release carrier, reducing the need for multiple substrates and secondary liners.
1. Dual Functionality
Having both an adhesive and a release coating means the same film can serve two essential roles:
- Bonding securely to surfaces or materials
- Releasing easily from adhesives or laminates
This duality simplifies production workflows, particularly in laminating, die-cutting, and coating operations.
2. Enhanced Durability
PET’s inherent chemical, thermal, and mechanical stability ensures the coatings remain intact even under demanding conditions — such as high-temperature curing, UV exposure, or solvent contact.
3. Consistent Release Performance
Silicone coatings provide controlled release levels, maintaining stable peel forces across production batches. This reliability is crucial in industries like medical tapes, electronics, and automotive, where consistency ensures performance and safety.
4. Strong Adhesion
On the adhesive side, advanced formulations deliver exceptional bonding strength without compromising flexibility. They adhere to metals, plastics, composites, or paper — and can be engineered for removable, repositionable, or permanent adhesion profiles.
5. Dimensional Stability & Printability
Biaxially oriented PET films maintain their flatness and dimensional integrity, making them ideal for printing, die-cutting, and registration-critical applications. PHC’s flexographic printing services (Flexographic Printing Service) can add color, branding, or functional graphics directly to coated films.
6. Chemical and Temperature Resistance
Dual-coated PET films withstand a wide range of temperatures (–70°C to 200°C) and resist moisture, oils, and solvents, making them suitable for high-stress environments and sterilization processes.
7. Process Efficiency
By combining two coating steps into one product, users experience:
- Reduced inventory and handling
- Faster production cycles
- Less waste and scrap
- Simplified lamination and die-cutting processes
Industry Applications: Labels, Graphics & Medical Tapes
The versatility of adhesive & silicone-coated PET films makes them indispensable in numerous sectors — from industrial labeling to healthcare.
1. Labels and Graphics
Dual-coated PET films provide both a printable surface and a release liner, enabling streamlined production of:
- Pressure-sensitive labels
- Decals and graphic overlays
- Protective transfer films
- Signage components
They deliver exceptional optical clarity, print adhesion, and release control, ensuring labels peel cleanly and apply flawlessly.
Explore PHC’s companion product: Silicone-Coated Release Films for additional liner options.
2. Medical and Healthcare Tapes
In healthcare, adhesive & silicone-coated PET films are used for:
- Surgical and wound care tapes
- Diagnostic patches
- Skin-contact adhesives
- Transfer films for medical devices
The silicone side ensures gentle release and patient comfort, while the adhesive side secures medical materials with precision.
3. Industrial and Electronic Applications
These films serve as:
- Carrier liners for double-sided tapes
- Protective interliners for electronic assemblies
- Insulating layers in circuits
- Bonding components in flexible displays or solar cells
Their stability under heat and stress ensures consistent performance in demanding industrial environments.
4. Automotive Components
In automotive design, dual-coated PET films are used in:
- Mounting tapes
- Decorative trims
- Sensor protection
- Wire harness wrapping
Their resistance to chemicals, heat, and vibration ensures durability and long-term adhesion even under extreme conditions.
5. Packaging and Protective Films
PET’s clarity, toughness, and sealability make it ideal for protective packaging, lamination layers, and surface-protection films. The silicone layer prevents blocking and aids easy unwinding or application.
Choosing a Local Polyester Film Partner
When sourcing adhesive & silicone-coated PET films, it’s not just about the material — it’s about who you partner with.
At Pilcher Hamilton Company, located in Greer, South Carolina (850 South Buncombe Road), we combine technical expertise with local service to provide tailored solutions for every application.
Why Choose PHC USA?
- Customization at Scale
Whether you need specific adhesive formulations, release levels, or thicknesses, PHC engineers collaborate to create made-to-order dual-coated films. - Full-Service Converting
Our facility offers coating, slitting, winding, die-cutting, and color printing — all under one roof. This reduces lead times and ensures consistent quality across every roll. - Rapid Turnaround & Local Support
Searching for “polyester near me”? PHC provides fast delivery throughout the Southeast and nationwide, with responsive support and flexible production scheduling. - Sustainability Commitment
We’re advancing toward more sustainable materials, including post-consumer recycled (PCR) PET and energy-efficient coating processes, aligning with circular economy goals. - Over a Century of Expertise
Since 1904, PHC has been at the forefront of polyester film innovation, serving industries from packaging and printing to automotive and healthcare.
Working with PHC: From Concept to Conversion
PHC’s team works directly with manufacturers, converters, and designers to develop films tailored to performance and brand requirements.
Typical collaboration includes:
- Material selection: Choosing the right PET base, thickness, and surface treatment.
- Coating design: Matching silicone and adhesive chemistries for optimal release and bond.
- Testing & validation: Evaluating peel strength, clarity, thermal stability, and print performance.
- Converting & logistics: Delivering finished rolls in precise dimensions, ready for lamination or printing.
We also integrate flexographic printing (see service here) to incorporate branding or functional markings directly onto coated PET, eliminating an extra process step.
For engineers and designers developing new products, PHC’s technical consultation ensures compatibility with adhesives, inks, and processing conditions — minimizing costly trial-and-error.
Sustainability and Material Innovation
As industries move toward eco-friendly materials, PHC leads with recyclable and PCR-based PET film options that maintain high performance while reducing environmental impact.
Our R&D efforts include:
- Solventless silicone systems to minimize VOCs
- Water-based adhesive formulations
- Recyclable liner constructions
- Energy-efficient coating technologies
By combining sustainability with functionality, PHC helps customers meet environmental targets without compromising quality or reliability.
One Film, Two Functions, Infinite Possibilities
In today’s high-speed, precision-driven industries, adhesive & silicone-coated polyester films represent a simple yet transformative material innovation. They bring together bonding and release, strength and flexibility, clarity and control — all in a single substrate engineered for performance.
From labels and graphics to medical devices and automotive components, these dual-coated PET films empower manufacturers to streamline processes, elevate product quality, and reduce costs.
For over a century, Pilcher Hamilton Company has been a trusted partner to converters, engineers, and designers seeking premium polyester film solutions — and we continue to set the standard in coating technology and customer care.
Whether you’re looking for PET release liners, dual-coated polyester, or simply the best polyester near me, we invite you to connect with our experts today.
📍 Visit us at:
Pilcher Hamilton Company
850 South Buncombe Road
Greer, South Carolina, USA
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