Polyester Film Manufacturing in the USA: Complete Industry Blueprint for 2025

October 22, 2025

At the heart of modern packaging, electronics, and industrial performance lies a material you encounter more often than you realize—polyester films. For more than 120 years, Pilcher Hamilton Corporation (PHC), located at 850 South Buncombe Road, Greer, South Carolina, has been advancing the converting of polyester films with precision and expertise. With over 10,000,000 lbs of inventory ready for immediate use and 24–48 hour delivery, PHC has become the answer for anyone searching “polyester near me” in the United States.

What Are Polyester Films?

Polyester films, often referred to as PET films or BOPET films, are high-performance plastic substrates known for their strength, clarity, chemical resistance, and dimensional stability. Their ability to withstand temperature fluctuations while maintaining optical properties makes them essential across countless industries.

For engineers and buyers looking to understand the technical details, PHC provides detailed film specifications and technical datasheets to guide accurate material selection.

Key Applications Across Industries

Polyester films are prized because they adapt to so many sectors:

Packaging: From food pouches to blister packs, PET films extend shelf life and preserve product freshness. Explore PHC’s polyester packaging applications to see how they serve diverse industries.
Barrier Laminates: High-performance BON PET laminations and barrier laminates deliver the toughness and protection brands require.
Adhesives and Graphics: As release liners, polyester films provide predictable performance. PHC’s dedicated release liner systems ensure adhesives remain intact until final application.
Electronics and Specialty Goods: Their dimensional stability and insulation properties make PET films integral to displays, flexible circuits, and protective laminations.

PHC’s Converting Services

The value of polyester films grows when they are tailored to customer needs. At PHC, converting is both art and science, supported by decades of investment in advanced equipment.

Slitting: Precision cuts that allow rolls to match exact widths.
Sheeting: Custom sheets that streamline downstream processing.
Winding: Controlled winding ensures flawless roll quality for converters.
Toll Converting: Flexible services for clients who need quick turnaround.
Coating: Surface treatments that add adhesion or performance.
Corona Treating: Enhanced surface energy for printing and laminating.

Beyond these, PHC also offers die-cutting, custom printing, laminating, and other specialty converting upon request. Essentially, PHC can take a raw polyester film and deliver it in the form that best suits your manufacturing process – be it narrow rolls, pre-cut sheets, or fully fabricated components.

Specialty Polyester Films

Not all polyester films are created equal. PHC offers a wide range of specialized options designed for targeted performance. For instance, we supply anti-fog films for refrigerated packaging, anti-static grades for electronics, and UV-resistant films for outdoor use. Need an opaque white film to block light? How about a high-clarity graphic film for printing brilliant images? Or perhaps a post-consumer recycled (PCR) polyester film to meet sustainability goals? PHC’s catalog covers it all. We even stock UL-certified electrical insulation films for transformers and motors, high-COF (coefficient of friction) films for easier handling on fast machines, and heat-sealable films that simplify pouch making.

This breadth means we can often match a film to whatever unique requirement you have. Our technical team can help navigate choices like matte vs. glossy, thickness and gauge, and whether a coated vs. uncoated surface will work best for your adhesive or ink. PHC works closely with customers to specify the perfect polyester film grade so that you get optimal results in your product.

Why Pilcher Hamilton Corporation?

PHC isn’t just another supplier—it is a partner with legacy. Since 1904, the company has stood at the forefront of polyester film innovation. Today, its 10 million+ pound inventory and strategic Greer, SC location (with quick shipping to all regions) make it uniquely capable of serving clients large and small. But beyond capacity and stock, PHC’s commitment to quality film and customer success is what truly sets it apart. We offer 48-hour fulfillment on many orders, custom fabrication services under one roof, and personal technical support from a team that lives and breathes polyester film.

When you choose PHC, you gain more than a supplier; you gain a knowledgeable ally ready to meet challenges head-on. Whether you’re developing a new eco-friendly packaging line or seeking a reliable domestic source to replace an import, PHC’s decades of experience and deep industry relationships stand at your service. We take pride in making polyester film solutions accessible, affordable, and hassle-free for American businesses.

Looking Ahead: Future Trends in Polyester Films

The polyester industry is rapidly evolving with sustainability at the center. Post-consumer recycled (PCR) PET, energy-efficient converting, and greener coating technologies are shaping the next generation of polyester films. PHC is actively involved in these trends, offering PCR film options and investing in processes that reduce waste and energy use. We foresee polyester films becoming even more ubiquitous as industries look to lightweight, durable materials to replace heavier substrates. And with advances in coatings, polyester films are taking on new roles – from flexible electronics to solar control window films.

In essence, the story of polyester film manufacturing is one of continual innovation. Pilcher Hamilton is proud to be part of that journey, driving progress from right here in the USA. We remain committed to being the polyester film manufacturer near you – ready to deliver the latest and greatest in PET film technology with the hometown service you deserve.

Polyester films power the products we use every day—quietly, reliably, and with unmatched versatility. From advanced barrier laminates to adhesive liners and high-tech displays, they are the unsung heroes making modern life possible. And as we’ve seen, having the right partner to navigate this world of films can make all the difference. Pilcher Hamilton Corporation invites you to join us in exploring what polyester films can do for you.Ready to explore polyester film solutions for your business? Pilcher Hamilton Corporation is here to help with expertise, inventory, and fast service. Whether you need a specific data sheet, a custom film sample, or a bulk order turned around quickly, our team is one call or click away. Feel free to contact us with your requirements or request a quote – we’ll respond promptly (often the same business day) to get you the PET film solutions you need. Experience first-hand why companies across the USA have trusted PHC since 1904 for all polyester film needs. Let’s innovate together with the power of polyester films!

The Power of Polyester Packaging Films: Top Applications & Innovations in the USA

Walk down any grocery aisle or open any medication package, and chances are you’re holding a product sealed with polyester packaging film. In the United States, polyester (PET) films have become a cornerstone of modern packaging – trusted to protect food, pharmaceuticals, and consumer goods with a combination of strength, clarity, and barrier performance. But what exactly makes PET the material of choice for so many packages, and how is an USA polyester film manufacturer like Pilcher Hamilton Corporation driving packaging innovations in 2025?

Pilcher Hamilton (PHC) has been at the forefront of packaging film solutions in America for decades. From its facility in Greer, SC, PHC supplies a complete packaging lineup of PET films that meet the needs of converters, brand owners, and manufacturers across multiple industries.

Our core product range includes metallized PET, PVDC-coated PET, heat-sealable PET, and twistable PET. Supported by PHC’s full product catalog and converting expertise, these films deliver packaging performance that’s both reliable and competitive.

Why Polyester Film is Essential in Modern Packaging

Packaging is a demanding arena for any material – it must keep products safe, fresh, and appealing, often under tough conditions. Polyester film shines in this arena due to a combination of attributes tailor-made for packaging:

Excellent Barrier and Protection: PET films provide a strong barrier against oxygen and moisture, which is vital for extending shelf life of foods and medicines. Even uncoated, PET’s barrier is good; and with metallization or coatings (like PVDC or acrylic), it rivals aluminum foil in keeping out spoilage factors. This makes high barrier PET indispensable for things like coffee, chips, and medical devices that are sensitive to air and humidity.
High Strength, Puncture Resistance: Thin PET films are surprisingly tough. They resist tearing or pinholing better than many alternatives. For instance, compared to common polyethylene film packaging, PET won’t stretch or puncture as easily, which means fewer leaks and product damage. Its tensile strength also allows down-gauging – using a thinner film to achieve the same strength as a thicker, weaker material. This leads to lighter packaging (reducing material use and cost) without compromising integrity. It’s one reason BOPET packaging films are used for heavy or sharp-edged products that might rupture other plastics.
Clarity and Gloss: Polyester films can be engineered to be crystal clear (“super clear” grades) or given a subtle haze or matte finish as needed. Their natural clarity and glossy surface make them ideal for showcasing products. For example, clear plastic film windows on packages or polyester film sheets for graphics allow high transparency. PET’s optical quality is a key reason it’s used in displays and printed polyester film overlays, where vividness and legibility are critical. Additionally, PET can be made in an opaque white version (by adding pigment) for light-sensitive products like dairy – offering opacity with the same smooth finish.
Heat Resistance for Sealing: PET has a higher heat tolerance than many packaging plastics. It doesn’t deform until it hits its glass transition around 78°C and even then softens gradually. This is important during heat sealing and filling processes. For example, hot-fill packaging (like bottling a hot sauce or pasteurizing a filled pouch) needs a film that won’t melt or warp. Heat-sealable polyester lidding films can withstand retort sterilization or microwave reheating. In contrast, low-density PE would fail at those temperatures. PET’s thermal stability also means packages can be coated or printed at high temperatures (e.g., during digital printing film runs or laminations) without shrinking or losing alignment.
Chemical Inertness & Safety: PET is inherently food-safe and approved by the FDA for direct food contact in many forms. It doesn’t impart taste or odor to contents – an important factor for sensitive food items (chocolate, spices, etc.). It’s also resistant to oils, acids, and alcohols, which are common in foods and cosmetics. Where some plastics might swell or weaken (for instance, polyamide films can absorb oils or moisture), polyester remains stable. This inertness makes it ideal for pharma blister PET films and healthcare packaging that demands a clean, non-reactive material. Plus, unlike PVC film (once common in blister packs), PET is chlorine-free and produces no harmful byproducts if incinerated, making it a more sustainable PET packaging choice.
Printability & Laminatability: A package not only has to protect – it has to sell. PET films accept inks and laminates well. With a corona treatment or print-friendly coating, polyester film packaging solutions yield excellent print quality for logos, nutrition info, and branding. Whether using flexographic, rotogravure, or digital printing, PET’s dimensional stability ensures registration stays accurate (graphics don’t skew due to film stretching). It also bonds well in laminates: for example, a layer of polypropylene and polyester together (PP for heat-seal layer, PET for strength/print layer) creates a versatile pouch structure. The PET layer provides stiffness and scuff resistance to keep the package looking good through transit and handling. Its compatibility with other plastics and adhesives is a big plus in designing multi-layer packaging materials.

In short, polyester film checks all the boxes for a packaging material: strong yet thin, clear or opaque as needed, heat-tolerant for processing, safe for food contact, and adaptable to various package formats. It’s little wonder that when packaging engineers evaluate options, PET often comes out on top as the film quality benchmark. Now, let’s look at specific ways these qualities are put to use in different packaging applications across the USA.

Key Applications of Polyester Films in Packaging

Polyester packaging films are used across numerous industries. Here are some of the most significant application areas in the U.S. where PET films make a difference:

Snack Foods & Confectionery: Metallized polyester is the go-to for chips, cookies, and candy wrappers. The shiny inside of a potato chip bag is often a thin metallized PET packaging film – it keeps oxygen and moisture out, ensuring crunchy freshness. Candy bars and twisted candy wrappers (like taffy or caramels) often use a special twistable PET film that holds a twist and doesn’t spring open. The combination of high barrier PET (sometimes referred to as Mylar food wrap) with colorful printing makes snack packaging both protective and attractive on store shelves. PET’s toughness also resists punctures from rough handling, which is crucial for snacks.
Coffee, Tea & Aroma-Rich Products: Coffee beans and specialty teas are sensitive to oxygen – exposure can ruin flavor. Polyester films laminated with barrier layers maintain aroma and freshness, essential for U.S. coffee and specialty tea brands. Many high-end coffee bags use PET as part of a multi-layer structure (often a PET/foil/PE laminate). The PET layer gives the bag strength, puncture resistance (coffee beans can be pointy), and an ink-friendly surface for branding. The same goes for spices, nuts, and jerky: high barrier PET pouches help lock in aroma and lock out moisture. And because PET can be made opaque (metalized or white), it protects these products from light which can degrade sensitive oils.
Frozen & Refrigerated Foods: When packaging frozen veggies, prepared meals, or ice cream novelties, polyester film plays a key role. Heat-sealable PET lidding films are used on frozen meal trays – they can be heat-sealed firmly to the tray and later peeled off by the consumer without tearing into bits. PET film doesn’t become brittle at freezer temperatures, so it won’t crack when flexed or dropped at -20°C. It’s also used as the print web in duplex structures (like a PET/PE laminate) for stand-up frozen food pouches, providing strength and a good printing surface, while a layer of polyethylene provides the actual seal. The result is a package that survives the freezer and seals tight, thanks to PET’s durability. Even in refrigerated foods like fresh pasta or deli meats, an opaque white PET film lid can prevent light spoilage while giving a clean, printable surface.
Pharmaceuticals & Medical Packaging: Polyester films are widely used in blister packs for pills, unit-dose medications, and medical devices. Pharma blister PET usually involves a PET film laminated to foil (forming a barrier layer) – the PET adds toughness so the blisters don’t crack and provides clarity if a window is needed to see the contents. Some blister packages use APET (amorphous PET) rigid film as the tray that is sealed with a foil/PET laminate lid. PET is also common in transdermal patch packaging, medical test strip pouches, and dissolvable film packets where purity and stability are paramount. Medical PET packaging often requires sterilization (ETO gas or gamma); PET’s chemical resistance and stability ensure it can handle these sterilization processes without degrading. Plus, using PET instead of PVC in hospitals is preferred now due to PET’s safer environmental profile.
Fresh Produce & Salads: To keep produce fresh while also visible, PET films with anti-fog coatings are used. If you’ve noticed salad bags or cut-fruit containers that don’t fog up in the fridge, that’s likely an anti-fog polyester film on the lid or window. These special coatings on PET prevent condensation droplets from forming, instead causing water to spread in a thin transparent layer. Consumers can see the food clearly, and the produce lasts longer because the package retains the right humidity. PET is a good choice here because it maintains clarity at cold temperatures and can be vented or perforated as needed while still staying strong.
Labels & Flexible Packaging for Beverages: Many beverage bottles (like sodas or juices) use PET shrink sleeves or wrap-around labels made from PET film. The shrink-sleeve labels are printed on a special shrinkable PET (PETG) that, when heated, conforms tightly to the bottle’s shape. This provides 360-degree branding. Polyester is replacing PVC in many shrink label applications for environmental reasons. Additionally, adhesive labels (stickers) for bottles often use a polyester face stock for durability – think of the labels on shampoo bottles or sports drinks that don’t disintegrate in water; those are frequently PET. Polyester label films hold up to moisture and friction, keeping the graphics intact. Finally, USA flexible packaging innovations often feature PET in multi-layer pouches for sports drinks, condiments, or gels, where durability and barrier are needed in a lightweight format.
Sustainable Packaging Initiatives: As noted earlier, there is a big push toward sustainability. In packaging, this means developing all-PET structures that are easier to recycle. For example, some frozen food bags are now moving to a single-material construction – an all polyester laminate – so that the entire pouch can be recycled as one unit (instead of being a mix of PET, PE, Nylon layers that can be hard to separate). Also, some brands use PCR polyester film in their packaging, advertising that the pouch or wrapper contains recycled content. These trends mean that PET’s role in packaging will likely grow even more, since it’s one of the few plastics that can meet performance needs and be readily recycled. Pilcher Hamilton works with clients to incorporate sustainable PET packaging options, like films with recycled content or designs that use less plastic overall.

As we can see, from snack packaging film to pharma blisters to anti-fog salad wraps, polyester film is deeply entrenched in virtually every segment of the packaging world. Its versatility allows it to serve as the clear window, the strong barrier, the printable skin, or the heat-sealable layer as needed. In the next section, we’ll discuss the specialized types of PET films (coated, metallized, etc.) that make these applications possible, and how a manufacturer like PHC provides a full lineup of packaging film solutions for every need.

PHC’s Specialized Polyester Films & Services for Packaging

To meet the diverse needs of packaging clients, Pilcher Hamilton provides a full lineup of polyester packaging films in specialized grades. Each grade is engineered for a particular performance:

Metallized PET: A PET film with an ultra-thin aluminum layer vacuum-deposited on it. This film offers superior barrier (for moisture/oxygen) and an attractive metallic gloss. Ideal for snack wrappers and coffee packaging. PHC’s Metallized PET film options include standard and high-bond versions (the latter ensures the metal layer adheres strongly even under flexing, so no barrier loss).
PVDC-Coated PET: A clear PET film coated with PVDC (polyvinylidene chloride) on one side. PVDC-coated films have exceptional gas and aroma barrier while remaining transparent. They are often used for high-barrier needs like meats, dairy, and pharmaceuticals where a metal foil is not desired. PHC supplies PVDC-coated PET in various coating weights to balance barrier vs. cost.
Heat-Sealable PET: These are PET films designed for secure, consistent seals for lidding, pouches, HFFS; helps reduce leaks and extend shelf life. PHC’s heat-sealable polyester grades simplify making pouches and lidding films – no need for a separate sealant layer like PE. They provide strong, tamper-evident closures on high-speed lines and can be formulated for peelable seals (useful for easy-open trays).
Twistable & Specialty PET: For candy and specialty wraps that require high twist retention, PHC offers twistable PET films in both clear and metallized versions. These films are engineered with higher stiffness and memory so that when you twist the ends of a candy wrapper, it stays twisted closed. PHC also carries opaque white PET for light-blocking needs (common in dairy and confectionery packaging), translucent PET for a frosted look, and chemical-treated PET that readily accepts inks and adhesives for excellent printability and laminating.

In addition to material variety, an advantage of working with PHC is the range of in-house services to customize films for your packaging line. We understand that each packaging machine has specific width, diameter, and core requirements – so we offer precision slitting to deliver rolls in the exact dimensions needed (PHC can slit down to very narrow widths, for example). We can also perform sheeting if flat polyester sheets are required (for instance, for printing or thermoforming). If you need printed film, PHC provides flexographic printing services or works seamlessly with print partners to supply pre-printed rolls with up to 8-color graphics. Our coatings and corona treatment capabilities mean we can take a base film and convert it into a ready-to-run packaging material – whether that means adding an anti-fog coating for produce film, a silicone release coating for easy-peel lids, or simply enhancing surface energy so your own inks adhere perfectly.

Crucially for packagers, PHC maintains a robust inventory of packaging-grade PET films. That means common specifications (thickness, treatments) are often ready to ship without long lead times. Need a 48-gauge metallized PET for a rush project? PHC likely has it on-hand in our climate-controlled warehouse, available to ship within 24 hours. Our team also offers film quality assurance – we provide technical datasheets and even sample rolls for testing so you can verify performance on your equipment before committing to full production orders. From idea to implementation, PHC supports your packaging film manufacturing needs every step of the way.

Whether you’re wrapping a granola bar, sealing a microwaveable entree, or developing a new sustainable pouch, Pilcher Hamilton’s specialized films and responsive services ensure you get the right PET film, tailored to your project, with the convenience of a U.S. partner. By combining a broad product lineup with custom converting, PHC truly delivers “polyester film packaging solutions” for every application under one roof.Finding the optimal packaging film can make or break a product. If you’re looking for guidance or a reliable source of polyester packaging films in the USA, Pilcher Hamilton Corporation is ready to assist. Our experts can recommend the right film for your specific application and supply it with industry-leading turnaround times. Feel free to contact our team for technical advice or a quote on any packaging film requirement. With PHC as your partner, you gain the confidence of working with an experienced U.S. manufacturer dedicated to keeping your packaging running smoothly and your products protected.

Polyester Films in Adhesives & Graphics: Release Liners and Converting Solutions

Pressure-sensitive adhesives (PSAs) are everywhere in modern life—from industrial tapes and medical devices to consumer labels and protective films. But adhesives are only as effective as the liners that protect and carry them. That’s where polyester (PET) release films come in.

At Pilcher Hamilton Corporation (PHC), we supply and convert premium PET films designed for release liner and PSA applications. Our portfolio includes silicone-coated release films, adhesive and silicone-coated base films, and advanced converting services such as die-cutting and winding/rewinding. With PHC, USA converters and brand owners gain reliable, high-performance materials that optimize production and deliver consistent adhesive results.

Why Polyester is the Go-To Film for Release Liners

When it comes to pressure-sensitive adhesive liners, the choice often boils down to paper vs. film. Polyester film has become the preferred liner material in many high-performance applications because of its dimensional stability and durability. Unlike paper liners, PET liners won’t tear or absorb moisture, and they maintain a consistent release force over time. Key reasons PET is the backbone of release liners and carrier films:

Dimensional Stability: Polyester film lies flat and stays flat. It doesn’t expand or contract significantly with humidity or temperature changes. This is critical for printed label liners or precision die-cut parts – the backing must hold exact registration. Silicone-coated PET liners keep their shape, ensuring that stickers or die-cut pieces align perfectly with their intended positions. By contrast, paper liners can curl or distort when humidity shifts, throwing off alignment in automated applicators.
Tear Resistance: If you’ve ever peeled a sticker and the liner ripped, you know how frustrating weak liners can be. PET liners have high tensile strength, so they resist tearing or snapping even if peeled quickly or at awkward angles. This property is crucial for industrial tapes and graphics where the liner might be large or removed rapidly on assembly lines. A pressure-sensitive adhesive liner made of PET gives the end-user a smoother experience – the backing comes off in one piece.
Smooth, Consistent Surface: PET film is extruded to a very smooth finish. When coated with release silicone, it provides a uniform surface that yields consistent release force (the effort needed to peel off). This means that from the first label on a roll to the last, the peeling force is predictable – important for machine-applied labels. The smoothness of a PET release liner film also ensures there are no fiber or dust contaminants (common with paper) that could transfer to the adhesive. Electronics manufacturers, for instance, prefer polyester liners to avoid particles on adhesive that could cause device failures.
Temperature & Chemical Resistance: Many adhesive processes involve heat (think of laminated graphics or certain tape manufacturing steps), and many end-uses see heat (like a sticker on a car window in summer). Polyester liners can handle elevated temperatures without deforming. They also resist chemicals and oils – an important trait for liners used in, say, automotive adhesive components or medical patches. PET liners won’t become saturated or weakened by exposure to oils, plasticizers, or solvents. This durability is why USA PSA liner films for critical applications (medical electrodes, automotive adhesives, etc.) are often PET-based.

In summary, polyester provides a reliable foundation for adhesives. It carries the sticky stuff from factory to final application, then cleanly departs the scene. For U.S. manufacturers of tapes and labels, using PET liners means fewer problems in production (like breaks or misalignment) and a better experience for the customer peeling off the liner. Next, let’s look at how PET films are engineered with release coatings to perform this role.

Silicone-Coated PET Release Films: Easy Peel, Precise Control

A release liner is only as good as its release coating. Most PET liners are coated with a very thin layer of silicone to achieve a desired release force. Pilcher Hamilton specializes in silicone-coated PET films that provide consistent, controllable release characteristics for different applications.

Using proprietary coating techniques, a curable silicone is applied to the PET film in a clean environment and cured (often UV or heat-cured) to bond to the surface. The result is a smooth, even silicone layer that interacts with adhesives in a predictable way. By adjusting the silicone formulation, PHC can offer liners with varying release levels – from easy-release (low peel force) for something like a large graphic decal that needs gentle removal, to tighter-release (higher peel force) for applications where the liner should stay put until a deliberate peel (such as heavy-duty industrial tapes). These are sometimes called “easy”, “medium”, or “tight” release liners in the industry.

One example is label stock: a mailing label sheet might use a PET liner with a release optimized so that labels peel off effortlessly by hand, but also don’t fall off the liner during printing and handling. Silicone-coated PET release films achieve that balance. Another example is double-sided tape rolls – they often have a PET strip as the liner, and you want the tape to unwind without the liner sticking too aggressively to the adhesive (which could cause jerky unwinding or tears). PHC’s silicone release films are designed for such performance, thoroughly tested for consistent peel across the web and from batch to batch.

Beyond standard silicone, PHC also provides specialty release coatings. For instance, some clients need a liner that will later be printed or processed after adhesive removal – for these, a adhesive-coated PET base might have a printable release surface or a modified silicone that allows further bonding. Others might require differential release (silicone on both sides of PET, each side with a different release level) – something often used in transfer tapes. PET is an excellent carrier for these complex coatings because it can be easily handled in coating machines and its stability ensures uniform coating weight.

In short, PET release liners with silicone coatings offer the best of both worlds: the strength and stability of polyester plus the tailored release properties of advanced silicones. Pilcher Hamilton’s expertise in marrying these components means our clients get liners that behave exactly as needed – the liner stays on when it should, and peels off smoothly when it’s time to stick the product. This reliability is crucial in high-speed label applicators and critical assembly processes.

PET Base Films for Tapes, Labels & Graphic Media

Polyester isn’t just used as a throw-away liner – it’s often part of the final product in tapes, labels, and graphics. Many polyester tape products use PET film as the backing (the part that remains with the adhesive). For example, electrical insulation tapes (like those yellow transformer tapes or motor slot liner tapes) are typically PET-based with an adhesive on one side. The PET provides strength, dielectric insulation, and temperature resistance, allowing the tape to withstand heat and stress in applications like coil wrapping. Even general-purpose office tape can use a thin PET backing for a higher quality feel (it tears less easily than cheap polypropylene tape).

In labels, while paper is common for short-life stickers, polyester labels are used when durability matters. Think of asset tags on electronics, safety warning labels on power equipment, or barcode labels on industrial components – these are often a polyester print film that’s been printed and then coated with adhesive. PET labels resist water, oils, and UV light far better than paper, so the text or barcode remains legible for years. They also don’t stretch or shrink, which keeps the scannable barcode dimensions stable. Pilcher Hamilton supplies PET films specifically for such graphics and label stock, including pre-coated varieties for better ink adhesion (so your prints don’t smear) and Adhesive & Silicone Coated Base Films that streamline label production by providing ready-to-bond surfaces.

Large-format graphics and decals are another area. For instance, the decorative graphics on appliances or the control panel overlays on machinery are often printed on PET film. This PET graphic film is then laminated to an adhesive and die-cut to shape. PET’s toughness ensures the graphic doesn’t scratch easily and can survive sunlight and cleaning chemicals. When producing these, manufacturers appreciate that PET stays dimensionally stable during printing and cutting – meaning the 100th decal is exactly the same size as the 1st. If a client needs a custom window or shape in the graphic, PHC can provide custom polyester converting – delivering pre-slit rolls or sheets of PET with the desired thickness, treatment (for ink or adhesive), and even pre-die-cut windows or holes if required.

A particularly specialized use is in the realm of die-cut insulating film pieces. In electric motor assembly, for instance, thin PET sheets are die-cut into intricate shapes that line motor slots (often a job for Nomex®/PET laminates, as mentioned earlier). PHC’s precision die-cutting services (using automated presses and laser-guided alignment) transform coated PET films into finished liner parts for electrical insulation, gasketing, labeling, and medical applications. The accuracy and repeatability of PET film – it doesn’t curl or vary in thickness – means tight tolerances can be held on these parts, which is critical for electrical performance. And because PET is tough, those parts won’t crack or shed during installation.

In all these cases – tapes, labels, graphics, and industrial die-cuts – PET film is providing form and function, not just temporary support. Pilcher Hamilton supports customers by not only supplying the base films but also helping convert them to the desired format. Need narrow rolls of 1/2″ PET tape backing? We’ll slit it. Need sheets of pre-laminated PET for printing labels? We can sheet it and even arrange coating. The combination of material and converting expertise means faster development cycles and a one-stop solution from raw film to finished component.Have a challenging adhesive or graphics project? Pilcher Hamilton can provide the tailored polyester film solution. From supplying the right silicone-coated PET liner to delivering custom-cut film parts, we’ve got you covered. Contact our experts to discuss your requirements – whether it’s a special release value, a tight tolerance die-cut, or a unique coating. As a U.S. polyester film specialist, PHC is ready to partner with you to improve your tape, label, and graphics products. Feel free to get in touch for samples, technical datasheets, or a quote on your next project.

Mylar® PET Film in the USA: What It Is & When to Specify

Mylar® is a name that has become practically synonymous with polyester film, especially in the United States. It’s common to hear engineers and hobbyists refer to any PET film as “Mylar,” much like one might say “Thermos” for a vacuum flask or “Velcro” for hook-and-loop fasteners. But Mylar is actually a specific brand of biaxially oriented PET film, originally developed by DuPont (now DuPont Teijin Films). So, what exactly is Mylar, and when does specifying Mylar® make a difference versus using a standard polyester film?

In this guide, we’ll demystify Mylar PET film. We’ll cover its defining properties and the legacy that made it famous in American industry. We’ll also explore key Mylar film USA applications – from electrical insulation Mylar films in motors and transformers, to Mylar packaging film for food and pharma – and why some projects still call out “Mylar” by name. Importantly, we’ll discuss how Mylar compares to other polyester films (including generics and other brands like Melinex®) in performance and cost. As a leading polyester film supplier, Pilcher Hamilton often guides customers on whether a “Mylar” spec is truly needed or if a standard PET film will do the job just as well.

By understanding Mylar’s place in the polyester family, you can make informed choices. Whether you’re seeking UL approved polyester for electrical applications or an archival Mylar for document preservation, knowing when to specify the brand and when to consider alternatives can save you time and money. Let’s start with the basics: what sets Mylar apart as a polyester film, and how did it come to stand for quality in the USA.

What Is Mylar® PET Film?

Mylar® is the registered trade name for a family of polyester films manufactured by DuPont Teijin Films. Essentially, Mylar is a high-quality biaxially oriented PET (BOPET) film. The material itself is polyethylene terephthalate, just like any other PET film, but the Mylar brand historically signified a film made to DuPont’s exacting specifications and quality standards.

The Mylar brand dates back to the 1950s when DuPont developed one of the first polyester films. Over the ensuing decades, DuPont Teijin Mylar earned a reputation for consistency and performance. For example, “Mylar Type A” became a standard translucent film known for its balanced tensile properties and excellent dielectric strength. Many engineers would specify “Mylar Type __” in designs to ensure they got a trustworthy material. In fact, some UL thermal and electrical ratings specifically list Mylar by name (e.g., UL approved polyester films for electrical insulation often refer to Mylar or equivalent).

So, is there a chemical or physical difference between Mylar and a generic PET film? In composition, no – Mylar is PET. The difference lies in manufacturing quality, surface treatment, and available grades. DuPont Teijin offers Mylar in various grades with different properties (optical clarity, surface roughness, thermal stability, etc.), each thoroughly tested. When you specify Mylar®, you’re essentially asking for a premium PET film with a known pedigree and perhaps certain guaranteed attributes. That said, many non-branded polyester films today can meet or exceed Mylar specs, thanks to advances in film technology worldwide. This is why PET film vs Mylar debates often come down to availability and cost rather than fundamental capability – the gap has closed.

One thing to note is that Mylar® is a biaxially oriented film (BOPET), meaning it’s stretched in two directions during production, which improves strength, stiffness, and thermal stability. But this is true of most packaging and industrial polyester films, not just the Mylar brand. Mylar’s identity comes from being a pioneer product and maintaining a broad catalog of specialized grades (for instance, Mylar RL for release liner, Mylar MO for motor insulation, etc.). In short, Mylar is a brand of PET film that has become shorthand for quality polyester film, particularly in the USA where it was introduced and heavily used in the late 20th century. Next, we’ll consider why someone might specifically call for Mylar in a project, and what benefits that brand implies.

Why Might You Specify Mylar® in the USA?

Given that many generic PET films now perform similarly, why do engineers still sometimes insist on Mylar specifically? There are a few scenarios:

Legacy Specifications and Trust: A lot of drawings and mil-specs from past decades simply call out “Mylar” because it was the gold standard. For example, a transformer design from 1980 might list “2 mil Mylar insulation wraps.” To avoid any ambiguity, some companies continue to specify the brand to ensure they get at least that level of quality. There’s a trust factor – Mylar® has decades of proven field performance in everything from NASA spacecraft (yes, Apollo missions used Mylar blankets) to the electrical insulation of countless motors and transformers in the USA. That legacy means specifiers feel safe with Mylar.
UL and Regulatory Recognition: In certain safety-critical applications, using a known material can simplify certification. Electrical insulation Mylar films, for instance, come with UL ratings for dielectric breakdown and thermal endurance (often Mylar is UL rated for thermal class B (130°C) or higher, depending on the grade). If an insulation system is UL listed with Mylar, manufacturers stick with it to maintain compliance. Similarly, Mylar is FDA compliant for many food-contact uses, and using the branded film can make regulatory paperwork a bit easier due to existing documentation. So if a project needs “UL listed polyester film” or long-term thermal aging data, specifying Mylar may expedite approvals.
Special Grades and Properties: DuPont Teijin offers some niche Mylar grades not readily found elsewhere. For example, Mylar EL is a low-shrink electrical grade that stays dimensionally stable at high temps; Mylar OL is pre-treated for superior adhesion of inks (useful in Mylar film printing for electronics); Mylar HA is heat stabilized for minimal thermal shrinkage. If an application truly needs one of these unique formulations, calling out Mylar by grade is necessary. Generic PET might not exactly replicate a specialized Mylar grade’s behavior (like super low shrink or specific surface chemistry). Another example is archival Mylar (often Mylar D or Melinex 516), which is certified for long-term document storage because it has no additives that could off-gas and harm paper – a library archivist might insist on the branded film for peace of mind.
Brand Perception and Marketing: Sometimes the end user market recognizes the Mylar name as a mark of quality. A manufacturer of high-end audio capacitors or kite foil might advertise that they use “genuine DuPont Mylar film” as a selling point, implying superior quality to generic polyester. In such cases, the spec isn’t just technical, it’s also marketing-driven.

In summary, specifying Mylar® usually comes down to leveraging its reputation, existing certifications, or unique grade properties. In many general-purpose cases, a standard PET film would perform equivalently, but the Mylar name carries assurance. For U.S. companies that have always used Mylar in a particular product, there’s also a validation cost to switching materials – so they often stick with what isn’t broken. Now, let’s look at where Mylar is commonly used and how it benefits those applications.

Applications of Mylar® PET Film in the USA

Mylar’s versatility means it shows up in many sectors. Here are some of its well-known uses:

Flexible Packaging & Balloons: In the packaging world, Mylar is often associated with the shiny, metallic film keeping snacks fresh. Those metallized potato chip bags or Mylar helium balloons that float at birthday parties – that’s metallized Mylar film (a PET film with a thin aluminum layer). While today any metallized PET could do the job, the term “Mylar bag” is still used generically for food storage pouches because of the brand’s history. Some specialty food and pharma packs still specify Mylar for its consistent quality in laminates.
Electrical & Electronics: One of the classic uses of Mylar is as an electrical insulation and dielectric. Mylar film is used to wrap motor windings, line transformer coils, and serve as an insulator in electronics. Mylar electrical insulation films are prized for high dielectric strength and reliability. Mylar capacitors (film capacitors using Mylar as the dielectric) were once very common – they’re stable and have low loss. Even today, for certain high-reliability electronics or aerospace circuits, designers might call for a Mylar or Melinex® film capacitor. Additionally, cable wraps and circuit board films sometimes use Mylar for its balance of toughness and insulation.
Labels, Overlays & Graphics: Mylar’s dimensional stability and printability make it popular in graphic arts. It’s used for things like reflective safety labels, durable equipment decals, and instrument panel overlays. In the era before CAD plotting, Mylar film sheets were the medium for technical drawings because they don’t tear or shrink – many architects’ blueprints were originally drawn on translucent Mylar. In the sign industry, Mylar stencils are used because they hold detail well and can be reused. And as mentioned, archival document sleeves are often made of clear Mylar D – ensuring precious papers don’t yellow or decay.
Industrial & Aerospace: Beyond the familiar, Mylar finds its way into various industrial uses. It serves as a release film in composite manufacturing (like during carbon fiber lay-up, a Mylar release film can prevent epoxy from sticking). It’s part of some adhesive tapes and gaskets. And famously, NASA’s spacecraft and lunar landers were swathed in gold-colored Mylar foil blankets – the material’s excellent infrared reflectivity and thermal stability protected equipment from extreme temperatures. That gold foil on satellites we see in photos is aluminized Kapton and Mylar. Mylar is also used in aviation for insulation blankets inside aircraft fuselages.

In short, Mylar® PET film finds use anywhere a high-performance plastic film is needed – from the mundane (chip bags and balloons) to the extreme (spacecraft and high-voltage transformers). Next, we’ll discuss how Mylar compares economically and technically with other polyester films, and how to source it (or alternatives) for your projects.

Mylar® vs. Other Polyester Films: Cost & Sourcing Considerations

In many cases, a standard polyester film can substitute for Mylar with identical results – often at lower cost or with faster availability. Mylar, being a branded product, can sometimes come at a price premium. Also, DuPont Teijin Films has specific production runs; certain Mylar grades might have longer lead times or minimum order quantities if they’re not in stock. This is where working with a supplier like Pilcher Hamilton can help. We advise customers on whether a generic polyester film can meet their needs or if the Mylar brand is justified.

Performance Parity: For general applications (packaging, basic electrical insulation, printing), there are Mylar film alternatives from other producers that match the key specs. For instance, a 100-gauge general-purpose PET from another manufacturer will likely perform the same as Mylar Type A in a given application. Pilcher Hamilton stocks a variety of such polyester films that we often recommend as drop-in replacements. We ensure they have similar thickness tolerance, tensile strength, clarity, and any needed certifications. Our Greer, SC warehouse might have a film on the shelf that saves you from waiting on a special Mylar order.
When Mylar is Worth It: If your project explicitly requires a unique Mylar grade (say a super heat-stabilized or UL-listed variant), Pilcher Hamilton can source genuine Mylar® for you. As a USA Mylar supplier, we leverage our network to obtain the specific grade and thickness you need. We can even arrange smaller quantities if DuPont’s standard ordering is too large for your needs, by piggybacking on our inventory orders. So, you’re not out of luck if you truly need the brand – we handle the logistics.
Polyester Film Brands: Aside from Mylar, other brand names in polyester film include Melinex® (another DuPont Teijin brand), Hostaphan® (Mitsubishi Chemical), and many more. Part of our role at PHC is translating a spec into an equivalent. If a drawing calls for “Melinex 454,” we can provide that or an equivalent film from another brand that has the same properties. We maintain a database of polyester film specs to cross-reference polyester film brands. Often, OEMs are open to equivalents as long as they get documentation that the replacement meets or exceeds the original spec.

In short, while Mylar® remains a benchmark, it’s not the only game in town. Modern PET films from various manufacturers offer broad availability and competitive pricing. By consulting with a knowledgeable supplier like Pilcher Hamilton, you can determine the most cost-effective option – be it authentic Mylar or a functionally identical polyester film – without compromising on quality. This flexibility can shorten lead times and save cost, all while ensuring your application gets the reliable PET film it requires.Need Mylar® or an equivalent polyester film? Pilcher Hamilton Corporation is ready to help. As a U.S. expert in polyester films, we can supply genuine Mylar grades for specialty needs or recommend cost-effective alternatives for your application. If you have questions about specifying Mylar vs. standard PET, or you need a quote on a particular film, our team is at your service. We pride ourselves on being more than a supplier; we’re a collaborator in solving your material challenges. Contact us here for personalized assistance and timely supply of polyester films anywhere in the USA.

Polyester Films in Industrial & Electrical Applications: A USA Manufacturer’s Guide

Polyester films aren’t just for packaging and labels – they also play a critical role in heavy industry, electrical systems, and cutting-edge technology. Thanks to their high strength, insulating properties, and chemical stability, PET films have become a workhorse material in manufacturing environments. Whether it’s serving as a dielectric in a motor, a high temperature PET film used for masking in powder coating, or a durable surface protection film on metal, polyester delivers performance at a reasonable cost. In this guide, we’ll examine how polyester films are utilized in industrial and electronic applications across the USA.

As one of the leading providers of polyester film solutions, Pilcher Hamilton (based in Greer, SC) works closely with companies in aerospace, automotive, electrical, and other sectors to supply and custom-convert PET films for their needs. We see firsthand the versatility of these films: one day we’re slitting electrical insulating polyester rolls for a transformer manufacturer, the next we’re die-cutting precision PET washers for an automotive client. If you’re considering polyester film for an industrial application, it helps to understand its capabilities and where it stands relative to alternatives like polycarbonate sheets or high-end polymers like Kapton® polyimide.

In the following sections, we’ll explore the strengths of PET film in demanding environments, address common comparisons (like Kapton vs polyester for insulation, or polyester vs polycarbonate for glazing and barriers), and highlight how an experienced film converter can adapt polyester to unique tasks. By the end, you should have a clearer picture of why polyester film (often reinforced or combined with other materials) is a mainstay in modern industry and how USA-based converting services support its use from prototype to production.

Strength, Durability & Versatility in Industrial Settings

In factories and workshops, polyester film often appears as an unassuming roll that solves very specific problems. One key attribute is its high tensile strength combined with tear resistance. For instance, PET films are used as protective barriers on equipment – a strip of high tensile plastic film can be draped over a machine to protect it from paint overspray or blasting grit, surviving where a thinner polypropylene film might rip. In metal fabrication, polyester films serve as temporary surface protectors on steel or aluminum sheets (preventing scratches during cutting or transport). They adhere via static or light adhesive and peel off without residue, thanks to PET’s toughness and chemical resistance.

PET film also shows up in unexpected mechanical uses. Have you ever seen those thin shim washers or gaskets in assemblies? Many of them are die-cut from polyester sheet stock. The material’s dimensional stability means even thin shims hold precise thickness and flatness. For example, tractor manufacturers might use 10-mil PET washers as spacers in joints – the industrial plastic film replaces what used to be metal shims, reducing cost and adding a bit of flexibility. And because PET doesn’t corrode or become brittle in cold, it can outlast some metals or plastics in such uses.

Another area of growth is polyester composite film uses. Polyester films are sometimes combined with other materials to create laminates tailored to industrial needs. A good example is in safety apparel: reflective strips on vests are often made by vapor-coating aluminum onto PET film and laminating it to fabric – the PET gives the strip its strength and houses the reflective layer. In flexible circuit boards for cars or appliances, PET film can be the substrate that holds copper circuits – it’s not as heat-resistant as Kapton polyimide, but for moderate temperatures it works and is far cheaper. Similarly, multi-layer polymer film sheeting can include PET as a structural layer in composites, providing an excellent strength-to-weight ratio.

In short, wherever an industry needs a thin, strong, stable material, PET film is a top contender. It won’t rust, it handles impacts better than glass or hard plastics in thin sections, and it’s generally more affordable than exotic films. Next, we’ll address how it compares to some high-performance alternatives in the realm of temperature and insulation, where materials like polyimide (Kapton) and others come into play.

High Temperatures & Insulation: Polyester vs. Polyimide (Kapton) and Others

One common question is where the limits of PET film lie, especially compared to high-temperature polymers. Kapton vs Mylar is a classic comparison: Kapton® is DuPont’s polyimide film that can withstand extremely high temperatures (up to 400°C) and is self-extinguishing (it won’t burn easily). Polyester (Mylar/PET) generally is rated for continuous use up to about 130°C, with some heat-stabilized grades pushing ~150°C. It will melt around 250°C and can burn, meaning it’s not suitable for the most extreme heat or where flammability must be near-zero. So, in applications like spacecraft electronics or certain aerospace wiring, Kapton is chosen over PET despite the much higher cost.

However, for moderate temperature ranges (say –70°C to +125°C), PET films perform admirably and at a fraction of the price of polyimide. Many UL insulating film systems in motors and transformers are built around PET (class B or class F insulation). When higher thermal class is needed, a common solution is to use composites: for instance, a Nomex-Mylar laminate (often called NMN) sandwiches PET film between layers of Nomex® aramid paper. The Nomex takes the brunt of high heat and provides flame retardance, while the PET adds mechanical strength and tear resistance. These laminates are widely used to insulate high-voltage coils, achieving Class H (180°C) ratings in a cost-effective way. PHC supplies such laminates to transformer manufacturers who need the best of both worlds.

In printed circuit applications, electrical insulating polyester sheets can be punched into insulating spacers, tube slot liners, or circuit board insulators. If the assembly will see only moderate heat, PET is preferred over more brittle plastics. For example, a Kapton vs polyester choice might come down to environment: in an automotive sensor that gets to 120°C, PET will do fine as an insulator and is much cheaper; but in a jet engine sensor at 250°C, PET would deform, so Kapton or PTFE is needed. It’s about matching the material to the mission.

We should note flame resistance: standard PET is not highly flame-retardant (it will burn slowly). There are specialty FR polyester film variants with flame-retardant additives, used in electronics to meet UL 94 VTM-2 or similar ratings. They trade a bit of mechanical performance for self-extinguishing behavior. When extreme flame resistance is needed, polyimides or fluoropolymers are still kings. But for many electrical assemblies in appliances or consumer electronics, a flame-retardant polyester film meets safety requirements at far lower cost.

In summary, polyester films cover a broad swath of mid-range thermal and electrical needs. They slot in below the ultra-high performance (and expensive) films like Kapton, but above cheaper plastics that can’t handle the stress. Knowing when PET is sufficient versus when to step up to polyimide is critical in design – and often PET is sufficient. A biaxially oriented nylon vs PET comparison is similar; nylon film can handle slightly higher temps than PET and is tougher against puncture, but it absorbs moisture and is less dimensionally stable. Often, PET wins out for its balance of properties in electrical insulation tasks.

Choosing a Specialized Film Partner vs. a General Plastics Supplier

One more consideration for industrial users is how you source and convert these films. There’s a big difference between ordering a slab of plastic from a general distributor and working with a film specialist. Large distributors (like Piedmont Plastics, which many businesses use for durable plastic sheet and rod stock) excel at bulk supply of common plastics (ABS, acrylic, polycarbonate, etc.). But when it comes to thin technical films, they may not offer the precise grades or conversion services you need.

This is where Pilcher Hamilton and similar specialists come in. We focus on polyester film manufacturing (USA-based converting) and distribution. Need a PET film with a specific surface treatment or in a non-standard thickness? A generalist might not even know it exists, but we likely have it or can get it. Need 1,000 punch-outs of a complex shape? We have in-house die-cutting and laser cutting to deliver finished parts – whereas a broadline supplier would just give you a roll and leave the rest to you. In short, working with a Greer SC film converter like PHC turns a raw material into a turnkey component for your assembly line.

Think of it this way: a general plastics supplier might sell you 48″ x 96″ sheets of 0.030″ PET. But what if you actually need 1″ x 3″ strips with rounded corners for an electrical bus bar insulation? You could set up a whole in-house cutting operation – or you can have us deliver those parts ready-made, inspected, and packaged. It’s often more economical to leverage our specialized equipment and expertise for such tasks. We regularly perform slitting and die cutting jobs to tight tolerances that most shops aren’t equipped for.

Another factor is polyester film tensile and quality grading. We carry industrial and MIL-spec grades of PET film and can certify properties like tensile strength, elongation, dielectric breakdown voltage, etc., if your project documentation requires it. General suppliers might not provide such data or the provenance of the film. When traceability and spec compliance matter (common in aerospace and medical projects), having a specialist partner is invaluable.

In essence, if polyester film is critical to your product or process, partnering with a company that lives and breathes films will save you headaches. Pilcher Hamilton has deep inventory, conversion capabilities, and technical know-how in the polyester arena. Instead of buying a raw material and figuring it out alone, you get a collaborator who helps adapt the material to your needs – whether that’s a certain polyester film industry standard or a custom fabrication. We often work hand-in-hand with clients’ engineers to fine-tune film solutions, something you won’t get from a catalog house.From prototypes to production, leveraging polyester film in industrial or electrical projects is easier with the right partner. Pilcher Hamilton Corporation is equipped to be that partner – offering not just material, but material expertise. If you’re looking for help selecting a PET film for a demanding application or need a quote on custom-converted film parts, our team is at your service. We pride ourselves on being more than a supplier; we’re a collaborator in solving your material challenges. Contact us to discuss your project and discover how a USA-based polyester film specialist can make a difference in your industrial or electronic applications.