Choosing the right USA polyester film manufacturer is about more than nominal gauges and data sheets—it’s about speed, reliability, and technical depth that shortens your path from concept to scale. Pilcher Hamilton operates from 850 South Buncombe Road, Greer, South Carolina, partnering with converters, brand owners, and OEMs to deliver films and services aligned to real production constraints—lead times, tolerance windows, and downstream process compatibility. Explore our Pilcher Hamilton homepage to see our broad capabilities, or go deeper into our history and the 120+ years of know‑how behind them. Whether your search starts with “polyester film manufacturer near me” or with a requirements list for COF, SIT, OTR, WVTR, your best next step is to connect with an engineer and align on specification. For a fast scan of formats, visit the polyester film catalog and the converting and finishing services overview—then schedule a spec review at our locations page or contact our team.
Callout — Why Pilcher Hamilton?
• 120+ years supplying performance films
• Full line of BOPET families, from Ultra Clear to High Barrier
• 24‑hour fulfillment (where stocked and feasible)
• On‑site converting: slitting, sheeting, winding, coating, corona treating, toll converting
• Local support in Greer, SC, to de‑risk timelines
Defining Polyester Films and Their Manufacturing Process
Polyester film—commonly referenced as PET or BOPET when biaxially oriented—starts with polyethylene terephthalate polymerized from terephthalic acid (or dimethyl terephthalate) and ethylene glycol. For manufacturing, the resin is dried, melted, and extruded onto a cooled casting drum to create a stable primary web. The magic is in orientation: stretching the web in the machine direction (MD) and then the transverse direction (TD) (or simultaneously) to engineer crystallinity, mechanical strength, thermal stability, and dimensional control. A heat‑setting stage follows to lock in properties, reduce shrinkage, and ensure flatness and handling stability for downstream printing, laminating, metallizing, and die‑cutting.
From PET Resin to BOPET Film: The Line at a Glance
- Resin Handling & Drying: PET chips are conditioned to precise moisture specs to prevent hydrolytic degradation, which would lower intrinsic viscosity and affect film strength.
- Extrusion & Casting: A melt stream is delivered through a slot die to a chill drum. Quench conditions determine initial clarity and amorphous structure.
- MD/TD Orientation: The film is stretched 2–4× MD and 2–4× TD (ranges are illustrative) to create balanced properties. Stretch ratios, line speeds, and temperature profiles govern tensile, modulus, and haze.
- Heat Setting: Thermal treatment stabilizes the film, minimizing shrink under downstream heat exposure (e.g., during sealing, metallization, or print curing).
- Edge Trim & Winding: Edge beads are removed; the film is slit to master roll widths and wound under controlled tension for flatness and roll structure.
Callout — Spec‑to‑Shipment in 24 Hours
For many standard SKUs and widths, Pilcher Hamilton offers 24‑hour fulfillment. Align your requirements, confirm availability, and plan logistics with All Services and Locations.
Surface Treatment: Why Corona Matters
Polyester is inherently low surface energy (~42 dynes untreated), which can cause printing, coating, or adhesive wet‑out issues. Corona treatment uses a high‑voltage discharge to raise surface energy, improving ink and coating adhesion. Target dyne levels depend on the process—printing, adhesive lamination, silicone release, or metallization. Treated surfaces can diminish over time; storage conditions matter. Learn about our corona‑treated PET film options and how we pair them with precision slitting to deliver line‑ready rolls.
Coating & Metallizing: Tunable Functional Surfaces
Beyond treatment, films can be coated (e.g., acrylic, silicone release, heat‑seal, anti‑fog, anti‑static, matte) or metallized (aluminum vacuum deposition) for enhanced barrier, sealability, printability, COF, or optics. Coating grammage, cure method, and surface chemistries are tuned to your application and converting approach. For programmatic needs, see roll‑to‑roll coating and our reference film specifications and technical datasheets to frame initial targets before sample trials.
Essential Properties for Industrial Use
Specifying polyester film for production demands more than a simple “clear” or “matte” descriptor. The following property families drive performance and yield on press or line.
Mechanical & Thermal
- Tensile strength / elongation (ASTM D882): Drives web handling, die‑cut integrity, and resistance to tear initiation.
- Modulus: Governs stiffness and curl in laminations and stacked layers.
- Heat stability: Heat‑set films resist shrink and wrinkling during sealing or curing.
- Dimensional stability: Control in both MD and TD matters for registration.
- Sealability: For heat‑sealable grades, the seal initiation temperature (SIT) and hot tack window define pack speeds.
Optical & Aesthetic
- Haze (ASTM D1003): From Ultra Clear display films to Hazy or Soft Matte aesthetic diffusers, haze levels are chosen, not incidental.
- Gloss / Clarity: Influences on‑shelf impact and barcode/print legibility.
- Color: Colored and polymer pigmented grades support graphics, brand cues, and light management.
Barrier & Surface
- OTR (oxygen transmission) & WVTR (water vapor transmission): Critical for shelf‑life and product stability; improved by metallized or coated structures.
- COF (ASTM D1894): Affects draw on FFS equipment, stackability, and slip behavior.
- Surface energy (dynes): Sets adhesion readiness for inks, lacquers, and adhesives.
Electrical & Dimensional Stability
- Dielectric strength: Important for electrical/electronics uses and certain industrial wraps.
- Thermal classing: Heat‑set BOPET tolerates elevated temperatures versus many polyolefins.
- MD/TD balance: Prevents curl and maintains register in multi‑ply laminations.
Property Tables (Typical Ranges)
Note: Values below are typical ranges for guidance only—final specification depends on grade, thickness, and processing. Always confirm with technical datasheets and film specifications.
Table 1 — Typical Properties by Film Family (illustrative ranges)
| Film Family / Type | Nominal Thickness (µm) | Haze % (ASTM D1003) | MD Tensile (MPa) (ASTM D882) | TD Tensile (MPa) (ASTM D882) | COF (ASTM D1894) | OTR (cc/m²·day) | WVTR (g/m²·day, 38 °C/90 %RH) | Notes |
| Ultra Clear BOPET (untreated) | 12–100 | 1–3 | 150–220 | 170–250 | 0.3–0.6 | 70–150 | 2–5 | Base clarity for print/laminate |
| Corona‑Treated BOPET | 12–100 | 1–3 | 150–220 | 170–250 | 0.3–0.6 | 70–150 | 2–5 | Improved ink/adhesive wet‑out |
| Heat‑Sealable PET | 12–50 | 2–6 | 140–210 | 160–230 | 0.2–0.5 | 70–150 | 2–5 | SIT window tuned by seal layer |
| Metallized PET | 8–30 | 2–6 | 150–220 | 170–250 | 0.3–0.6 | <1–5 | <0.5–1.5 | High barrier; reflective |
| PvDC‑Coated PET | 12–36 | 1–4 | 150–220 | 170–250 | 0.3–0.6 | 0.5–5 | 0.3–1.5 | Enhanced barrier; coating weight matters |
| Anti‑Fog PET | 12–50 | 2–6 | 150–220 | 170–250 | 0.2–0.5 | 70–150 | 2–5 | Water‑shedding topcoat |
| Anti‑Static PET | 12–100 | 2–6 | 150–220 | 170–250 | 0.2–0.5 | 70–150 | 2–5 | ESD management for handling |
| Soft Matte / Hazy PET | 12–125 | 10–70 | 140–210 | 160–230 | 0.3–0.6 | 70–150 | 2–5 | Controlled diffusion/gloss |
| PCR‑Content PET | 12–100 | 1–6 | 150–220 | 170–250 | 0.3–0.6 | 70–150 | 2–5 | Sustainability; spec by PCR % |
| Specialty Coated PET | 12–125 | 1–10 | 150–220 | 170–250 | 0.2–0.5 | 5–120 | 0.5–3 | Tailored for inks/adhesives |
Mid‑Page CTA: Ready to validate a shortlist? Explore technical datasheets, or browse the polyester film catalog, then schedule a quick consult via Contact Us.
Applications Across Sectors Like Packaging and Electronics
Pilcher Hamilton’s portfolio is engineered for a breadth of uses—from fast‑moving consumer goods to industrial insulation and graphics.
Packaging: Overwraps, Lidding, and Barrier Laminations
- Snack & Confectionery Overwraps: Clear, matte, or metallized structures; set COF and SIT for high‑speed wrapping; pair heat‑sealable PET with barrier layers as needed.
- Coffee & Dry Goods: Metallized PET or PvDC‑coated PET to balance OTR/WVTR; glare control via matte face stocks; register‑stable for gravure/flexo.
- Pharma & Healthcare: Ultra Clear and High Barrier films supporting moisture/oxygen stability; corona or primer readiness for validated inks/adhesives.
- Fresh Produce / Anti‑Fog: Coatings that shed condensation; anti‑fog PET maintains product visibility.
- Sustainability: PCR options (when program‑compatible), downgauging to reduce material intensity.
Graphics & Labels, Release Liners, and PSAs
- Graphic Overlays: Ultra Clear and Soft Matte with scratch‑resistant coatings; consistent dyne levels for screen/UV ink systems.
- Labels & Wraps: Corona‑treated PET with controlled COF; dimensional stability minimizes curl and registration drift.
- Release Liners & PSAs: Silicone‑receptive and low‑energy back sides engineered for peel, unwind, and smooth lamination onto adhesive stacks.
Capability Tie‑In: Converting quality often decides yield. Use our precision slitting and tight‑tolerance sheeting to improve uptime and reduce splice‑related scrap. For engineered stack‑ups, roll‑to‑roll coating and corona‑treated PET film streamline readiness for ink, adhesive, or metallization.
Electronics, Electrical, and Industrial
- Electrical Insulation: Heat‑set BOPET with robust dielectric performance, cut to precise widths for slot liners, separators, and wraps.
- Flexible Electronics & Displays: Ultra Clear, low‑haze films with tight planarity for optical stacks; stable across cure cycles.
- Industrial Spacers & Carriers: Dimensional stability and stiffness for kiss‑cut parts; anti‑static coatings for handling safety.
Benefits of Choosing a Local Polyester Film Manufacturer Near Me
Selecting a polyester PET film supplier near me is a strategic risk‑management choice. Here is how local manufacturing translates into operational value.
Lead Time, Logistics, and Risk Reduction
- Shorter transit reduces exposure to lane volatility, port congestion, and cross‑border delays.
- Faster replenishment (including 24‑hour fulfillment on many stocked SKUs) safeguards continuity.
- Simplified claims & communication: Onshore visibility accelerates corrective actions and continuous improvement.
Plan Your Lane: Map your operations to Pilcher Hamilton’s locations and coordinate lead times with a production specialist via contact us.
Engineering Access and Project Velocity
- Spec refinement sessions: Align on gauge, treatment, coating, and SIT vs. line temperatures.
- Pilot‑to‑production transitions: Faster iteration cycles with nearby converting and sample roll availability.
- Documentation: Ready access to film specifications and technical datasheets expedites approvals.
Flexible Converting: Slitting, Sheeting, Winding, Coating, Toll Converting
Pilcher Hamilton’s integrated converting ecosystem enables you to buy only what your line needs—at the width, OD, core ID, and finish that maximize uptime.
- Precision Slitting: Tight edge quality, slit‑width tolerance control, and roll geometry that runs.
- Tight‑Tolerance Sheeting: Square, flat sheets to spec for die‑cut and lay‑flat needs.
- Custom Winding: Core IDs, OD targets, and roll builds aligned to your unwind and splice routines.
- Roll‑to‑Roll Coating: Functional surfaces (e.g., acrylic primers, anti‑fog, matte).
- Corona Treating: Dyne targets for inks, adhesives, metallization, and liners.
- Toll Converting: Bring your own web; we convert to the exact format your equipment expects.
Callout — Converting as a Speed Lever
Shorten changeovers, increase first‑pass yield, and keep operators in spec by buying line‑ready formats. See All Services for the full converting menu.
Sustainable Advances in Polyester Production
Sustainability is a design imperative. Polyester has unique advantages—mechanical strength, thin‑gauge capability, and recyclability pathways—that let you do more with less.
PCR Content and Circularity
Projects that specify PCR (post‑consumer recycled) content support circularity initiatives. PCR levels are set to maintain performance and aesthetics while meeting program targets. For critical clarity applications, blend recipes and filtration can preserve optics.
Process Efficiency and Waste Reduction
- Downgauging: A thinner gauge that preserves barrier or stiffness can materially reduce footprint.
- Converting waste minimization: Slit plans tailored to your widths maximize parent roll utilization; targeted OD and splice management reduce scrap.
- Onshore logistics: Shorter transit = lower transport emissions.
Design for Recyclability
- Monomaterial packaging with PET dominance can simplify sortation and recovery in compatible streams.
- Coating selection considers repulpability and recycling impacts; where high barrier is required, tailor the structure to your end‑of‑life reality.
Sustainability Note: Align sustainability goals with performance needs through an engineering consult. Start with All Products, then plan your test matrix via Technical Datasheets.
Specification & Procurement Checklist
Use this checklist to transition from research to a purchase‑ready specification:
- End‑Use & Line Constraints
- Packaging, PSA/liner, graphics, electrical/industrial
- Web path, tension range, nip/rewind limits
- Thermal exposure (sealing, curing, sterilization)
- Packaging, PSA/liner, graphics, electrical/industrial
- Base Film
- Gauge (µm) and web width
- Heat‑set requirements and dimensional stability targets
- Haze / clarity requirements (per ASTM D1003)
- Gauge (µm) and web width
- Surface Engineering
- Corona treatment (target dyne, one/both sides)
- Coatings: acrylic primer, ink‑receptive, anti‑fog, anti‑static, matte, heat‑seal
- Metallization considerations (if barrier required)
- Corona treatment (target dyne, one/both sides)
- Barrier
- OTR / WVTR targets and test conditions
- Structure (clear vs. metallized vs. coated) and seal layer
- OTR / WVTR targets and test conditions
- COF & Handling
- ASTM D1894 targets for slip and machinability
- Sticking, blocking, scuff tolerances
- ASTM D1894 targets for slip and machinability
- Converting Format
- Slitting: final slit widths, tolerance, edge quality
- Sheeting: cut size, squareness, flatness
- Winding: core ID (e.g., 3″ or 6″), OD target, roll structure
- Packaging: interleaving, wrap, labeling
- Slitting: final slit widths, tolerance, edge quality
- Documentation & Qualification
- Confirm film specifications and technical datasheets
- Request sample rolls/sheets
- Validate on line; update spec with measured results
- Confirm film specifications and technical datasheets
- Commercials
- Lead time, 24‑hour fulfillment eligibility
- Lead time, 24‑hour fulfillment eligibility
MOQ, blanket orders, replenishment cadence.
FAQs
1) What makes Pilcher Hamilton a top USA polyester film manufacturer for “near me” searches?
Proximity, engineering access, and a broad film portfolio backed by 120+ years of experience. Being based in Greer, SC reduces transit risk and accelerates trials and replenishment.
2) Can you really ship within 24 hours?
For many stocked SKUs and common widths, yes—24‑hour fulfillment is available where feasible. Coordinate availability and pickup windows via Contact Us.
3) Which film families do you offer?
A wide range including Anti‑fog, Anti‑static, Coated, Colored, Corona Treated, Clear High Barrier, Hazy, Heat sealable, High barrier, Metallized PET, PCR, Polymer pigmented, PvDC, Shrinkable, Soft Matte, Specialty Coated, Twistable, Tactical, Ultra Clear.
4) What converting services are in‑house?
Slitting, sheeting, winding, printing, die‑cutting, corona treating, coating, and toll converting.
5) How do I choose gauge and finish?
Start with end‑use and line constraints (speed, sealing, optics), then match gauge, haze, COF, and SIT to your equipment. Use our film specifications and technical datasheets to shortlist candidates.
6) What standards should I reference in my specification?
Commonly: ASTM D882 (tensile), ASTM D1003 (haze), ASTM D1894 (COF), ASTM F1249 (WVTR). Align test conditions with your end‑use and qualification plan.
7) Do you provide metallized and coated barrier options?
Yes—metallized PET and coated films (e.g., acrylic, matte, heat‑seal, anti‑fog, anti‑static, and others) are available. Discuss barrier targets (OTR/WVTR) to select the right stack.
8) Can you support release liner projects for PSAs?
Yes. We pair base film with surface treatment or primer and silicone‑receptive chemistries, then slit/sheet to press‑ready formats.
9) What information do you need to quote quickly?
Gauge, width, target COF, dyne requirements, roll OD and core ID, finish (treated/coated), and annual demand. Share any line constraints and sample needs via Contact Us.
10) Where are you located?
850 South Buncombe Road, Greer, South Carolina. Plan a visit or route freight via our locations page.
11) Can you work with customer‑supplied webs?
Yes—see toll converting to convert your material into exact formats for your lines.12) Do you offer documentation for audits and approvals?
Yes—technical datasheets and film specifications help streamline compliance and customer audits.
Selecting a USA polyester film manufacturer is a decision about performance, risk, and time. With 120+ years of film expertise, a comprehensive portfolio from Ultra Clear to High Barrier, and integrated converting—including slitting, sheeting, winding, corona treating, coating, and toll converting—Pilcher Hamilton is built to meet “polyester film manufacturer near me” expectations and exceed them with 24‑hour fulfillment where stocked. If your production plan calls for precise gauges, defined COF, dyne targets, barrier windows, and line‑ready formats, our team in Greer, South Carolina (850 South Buncombe Road) is prepared to help you move from spec to shipment—fast.Start by mapping your route via Locations and initiate an engineering consult through Contact Us. For pre‑work, browse All Services and check Technical Datasheets to accelerate your qualification cycle.