Polyester & PET Films in America: A Practical Handbook for Packaging, Labels, and Electronics

Polyester (PET) films are strong, versatile plastic films known for high clarity, strength,
and thermal stability, making them a top choice in U.S. packaging, labeling, electronics, and more. This
guide explains what PET films are, where they excel, who uses them, how to specify them, and why
choosing an experienced American supplier like PHC can reduce risk. We cover PET’s core properties,
compare it with other plastics, map common U.S. applications to the best film types, and detail key film
features (from metallized barriers to anti-fog, matte, and heat-seal coatings). You’ll also find guidance on
U.S. sourcing, lead times, pricing factors, and supplier vetting—plus real case notes, a glossary of PET film
terms, and 25+ FAQs. By the end, U.S. buyers will have a practical playbook on polyester films, backed by
PHC’s 120+ years of expertise, 3M+ lbs inventory, and fast nationwide shipping.

• Polyester films (PET) are thin, strong plastic sheets with high clarity and durability, used widely in
  packaging, labels, electronics and more.
• PET vs. other films: PET offers exceptional mechanical strength, thermal stability, and oxygen barrier
  versus many plastics, though it requires coatings for heat sealing.
• Common U.S. uses: From snack packaging and bottle labels to face shields, ID cards, and solar panels, PET
  films provide the needed clarity, strength, or insulation.
• Specifying PET film: Buyers should consider thickness, coatings (metallized, anti-fog, etc.), surface
  treatments (corona, matte vs. gloss), and compliance needs (FDA, UL).
• Why PHC: Pilcher Hamilton Company (founded 1904) is a trusted U.S. PET film supplier with 3M+ lbs in
  stock, 24–48h shipping, custom converting, and documented quality.

Polyester (PET) Films 101

Polyester (PET) film is a biaxially oriented thermoplastic film with high tensile strength, optical clarity, and thermal
stability, making it a go-to material for countless U.S. packaging and industrial applications.

What They Are & Core Properties

PET films are thin, flexible sheets of polyethylene terephthalate known for exceptional strength, clarity, chemical
resistance, and electrical insulation properties.
Polyester film (often referred to by the brand name Mylar®) is a type of plastic made by extruding and
stretching PET polymer into thin sheets . This biaxially oriented PET (BOPET) process imparts high
tensile strength and dimensional stability. PET film is transparent by default, offering up to ~90% light
transmission with low haze . Mechanically, it is very strong (tensile strength often 20,000–30,000 psi ),
resistant to tearing and puncture, yet remains flexible. Thermally, PET film can withstand a wide
temperature range—many general-purpose PET films are stable from about -70°F to 300°F, with some
electrical grades surviving up to ~180°C (356°F) continuous . It also has excellent dielectric strength
(withstanding high voltages without breakdown) , making it a trusted insulator in electronics. PET resists
oils, solvents, and moisture uptake (water absorption ~0.4%) , ensuring performance in humid or
chemical-exposed environments. These core properties—clarity, strength, thermal stability, and electrical
insulation—make polyester film one of the most versatile engineering plastics in foil or film form.

PET vs. Other Plastics: Clear Wins & Tradeoffs

Compared to polypropylene, polyethylene, or polycarbonate films, PET offers superior strength, heat resistance,
and oxygen barrier, but it requires special coatings for heat sealing and isn’t biodegradable.

Mechanical & Thermal Advantages: Polyester film stands out for its combination of stiffness and heat
tolerance. For example, PET film has far higher tensile strength and modulus than polyethylene (PE) or
polypropylene (PP) films , meaning it won’t stretch or tear as easily. It also handles higher
temperatures than polyolefins—PET’s melting point (~254°C/490°F) is much higher than PP (~160°C) or PE
(~120°C)—so PET can endure processes like sterilization or high-temperature electrical uses where others
might deform. Unlike polycarbonate (PC) film, which can offer similar clarity and strength, PET is less
expensive and generally has better moisture and chemical resistance . PET film also has a naturally
higher dielectric strength than PC film (e.g., ~21 kV/mm vs ~18 kV/mm at 10 mils) , which is valuable for
insulation.

Barrier & Clarity: PET provides an excellent oxygen barrier (important for food packaging), outperforming
untreated PP or PE which are more permeable . For instance, thin PET film might have an O₂
transmission rate an order of magnitude lower than similar-gauge BOPP film, keeping snacks and foods
fresher. However, PP excels in moisture barrier, meaning PP films prevent water vapor transmission better
than PET . This is why many packaging laminates pair PET with PE or PP layers – each contributes its
strength. In terms of clarity, PET and polycarbonate are among the clearest films; PP can be clear but tends
to have slightly less optical gloss. PET is naturally glossy and highly transparent, giving it a visual edge for
displays and labels .

Tradeoffs: One key difference is heat sealability. Polyolefin films (like LDPE or certain BOPP) can heat-seal
to themselves easily at relatively low temperatures, whereas pure PET film will not seal to itself without a
special coating or lamination (its seal initiation temperature is very high). Thus, PET often needs a heat-seal
layer (like a copolymer coating or a laminated PE layer) for use in pouches or lidding . Also, PET film is
generally produced in thinner gauges (commonly up to 10 mils thick) – thicker plastic sheets for heavy-duty
uses often turn to polycarbonate or PVC. PET is not biodegradable, whereas newer bio-films (PLA,
cellulose) offer compostability (though with performance compromises). It can generate static without
additives (requiring anti-static treatments for electronics uses ). Finally, in terms of cost, PET film is
usually more expensive per pound than commodity PE or PP film, but its durability can allow using a thinner
PET to do the job of a thicker, weaker film. Buyers weigh these factors: PET’s superior strength, clarity, and
barrier often justify its use, while coatings or laminates can mitigate its sealability and moisture barrier
gaps. For many U.S. packaging and industrial applications, PET film hits a sweet spot of performance that
other plastics can’t match, especially when long-term stability is needed

U.S. Applications & “Best‑Fit” Film Types

Polyester films are found across numerous U.S. industries. Below we highlight major application areas and the PET
film grades or treatments that best fit each use case.

Food/Flexible Packaging (Snacks, Produce, Lidding, HFFS/VFFS)

PET films are widely used in food packaging for their strength and flavor protection—often with metallized or
coated grades to provide oxygen barrier, heat-seals, and extend shelf life.

Snack Foods & Pouches: Many American snack packages (chips, cookies, nutrition bars) use a PET film
layer for its strength and printability, usually laminated with a sealant. Metallized PET is common for
improved barrier – a vacuum-deposited aluminum layer dramatically reduces oxygen transmission and
blocks light, preventing rancidity and flavor loss . For example, metallized PET in a potato chip bag
keeps oxygen and UV out, greatly extending shelf life. (See metallized polyester films for snack
packaging for more on this.) Clear high-barrier PET (e.g. with a PVDC or ceramic coating) is used when a
product window is needed. Lidding films for trays and tubs often use heat-sealable PET that has a special
copolymer layer allowing it to bond to trays – this provides the strength of PET with the convenience of a
peelable seal. In fact, heat sealable PET films for efficient packaging help ensure consistent seals on
HFFS/VFFS machines without sacrificing tensile strength.

Produce & Prepared Foods: Fresh produce packaging (like salad bags or cut fruit pouches) may use PET for
its clarity and toughness. Breathable anti-fog PET lids are popular for salad bowls – the anti-fog coating
prevents condensation so consumers can see the product. For ovenable or boilable pouches (e.g. frozen
vegetables steamer bags), PET’s high heat resistance is crucial; a 0.5–1 mil PET layer can survive hot-fill or
reheating temperatures that polyolefin films could not. PET films used for food contact are available in FDAcompliant
grades (PHC offers such films and provides FDA documentation per quoted specs). Also, U.S.
snack and candy wrappers sometimes use twistable PET for wrapping candies – this special grade of PET
retains a twist when you wrap it, similar to foil, useful for confectionery packaging. In summary, for food
and flexible packaging, PET’s role is usually as a structural or barrier layer that keeps packages strong,
shiny, and shelf-stable, often paired with other films for sealing. The result is packages that look appealing
(clear or metallic), run efficiently on U.S. packing lines, and protect contents for extended periods.

Labels & Graphics (Printability, Outdoor Durability)

Polyester films are a go-to choice for high-end labels, decals, and graphic prints due to their exceptional
printability (with proper treatment), dimensional stability, and weather resistance.

Prime Labels & Decals: PET film is commonly used as label facestock – the printable film that becomes the
label. Ultra-clear PET facestock yields “no-label look” clear labels on bottles, while white or metalized PET
films provide opaque labels with a premium feel. PET’s stiffness lets labels run at high speed with less
stretching than PE labels. However, PET’s surface typically needs a treatment or coating for ink adhesion:
corona-treated PET or an acrylic topcoat is applied so that inks and toners bond well . Once treated,
polyester offers excellent printing quality (fine text and vibrant images). It also handles die-cutting and
application without tearing. (For more details, see transparent polyester films for labels and graphics
which covers high-clarity label films.)

Durable & Outdoor Graphics: Because PET film is dimensionally stable and weather-resistant, it’s favored
for applications like outdoor decals, signage overlays, and vehicle graphics. It doesn’t expand/contract
much with humidity or temperature, so printed graphics stay aligned. Also, PET does not become brittle in
sun exposure if it’s UV-stabilized (additives can be included to block UV). For harsh environments, matte
polyester films are often chosen to reduce glare and hide scratches – e.g., a matte PET overlay on a
machine panel avoids reflection and fingerprints. (See our comparison table Matte vs. Gloss below.)
Additionally, PET films can be hard-coated with an anti-scratch or anti-graffiti layer for signage and touch
panels . Many U.S. parking permits, equipment nameplates, and barcode labels are printed on polyester
for longevity. PET labels can withstand moisture, chemicals, and UV better than paper or vinyl, making them
ideal for asset tags or bottle labels that won’t fall apart in ice buckets. Some specialized PET label films are
voiding or tamper-evident (they fracture or leave a pattern if removal is attempted). In summary, for
graphics and labels where print quality and durability are paramount, polyester film is usually the “best-fit”
substrate. It delivers a crisp print surface and remains intact and legible through all conditions.

Comparison: Matte vs. Gloss PET Label Films

Attribute	Gloss PET Film	Matte PET Film
Appearance	Shiny, high-gloss finish – vibrant shine	Flat, non-reflective finish – subdued look
Glare in light	Can produce glare under bright light	Low glare – easier to read under harsh light
Print Color Vibrancy	Colors appear very bold and saturated	Colors slightly muted (soft, premium appearance)
Fingerprints & Scratches	Fingerprints and scratches are more visible	Hides fingerprints and minor scratches better
Typical Uses	Product labels that need shelf “pop,” clear bottle labels for the no-label look, high-gloss stickers	Industrial equipment labels, outdoor decals (to reduce glare), any application needing a writable or scuff-resistant surface

Electronics & Electrical (Insulation, Flexible Circuits)

In electronics, PET films (often referred to as Mylar) serve as high-quality insulators, substrates for circuitry, and protective layers thanks to their dielectric strength and stability.

Electrical Insulation: Polyester film has long been a staple in electrical insulation for motors, transformers, and circuit boards. In the U.S., UL-approved PET films (like DuPont Teijin Mylar® or Melinex® grades) are used as slot liners in motors or as dielectric layers in capacitors. The film’s high dielectric breakdown strength and heat resistance (often rated Class B 130°C or higher) allow it to replace heavier materials. For instance, a thin (5–10 mil) PET insulator in a motor can withstand thousands of volts without failure. PET is also dimensionally stable, so it won’t shrink or creep over time, preserving insulation gaps. It does not corrode or support fungus, which is important for long-term reliability. Many electrical tapes use PET as the backing (often combined with adhesive) to create flame-retardant or high-temperature tape for coil wraps. PHC supplies electrical insulating polyester films that meet UL standards for dielectric strength (PHC confirms UL compliance per spec for these grades).

Flexible Circuits & Components: In the electronics manufacturing sector, BOPET films act as a substrate for flexible printed circuits, membrane switches, and display components. Polyester’s smooth surface and stability under soldering temperatures (briefly up to ~150°C) make it suitable for printing conductive inks to create circuits (for example, inside a keyboard or a medical test strip). A classic example is the silver ink traces on a PET film in a flexible PCB. PET is cheaper than high-end polyimide and sufficient for many circuits that don’t see extreme heat. Additionally, many capacitors are made with metallized PET film rolled up – these film capacitors leverage PET’s low dissipation factor and consistent dielectric. In displays, PET films are used as diffuser sheets or reflective layers; e.g., an LCD may contain white opaque PET to scatter backlight evenly. Also, EMI/RFI shields can be PET film metallized with aluminum or copper to create a lightweight shield layer. One emerging use is in wearable electronics, where PET’s flexibility and biocompatibility (PET is used in medical patches too) make it ideal. For a deep dive, How BOPET Films Are Revolutionizing Electronics Manufacturing (2025) covers cutting-edge uses of polyester films in electronics. Overall, PET’s role in electronics and electrical is as an insulating, stable base material that ensures devices run safely and reliably, from household appliances to high-tech gadgets.

Medical & Protective (Face Shields, Diagnostics, Device Covers)

Medical and protective applications rely on PET films for optical clarity, cleanliness, and strength—from anti-fog face shields to diagnostic test strips.

Face Shields & PPE: Clear PET films were widely adopted for protective face shields and safety visors in the U.S., especially in healthcare. PET’s advantages here are crystal clarity (for an unobstructed view) and impact resistance (it won’t shatter like acrylic glass). Most face shield films are around 7–10 mil thick PET, often with an anti-fog coating on the interior so that breath moisture doesn’t condense. PHC offers high-quality coated PET films specifically for face shields that meet optical grade standards (no distortion) while being easy to die-cut into visors. If you’re looking for high quality coated PET films for face shields in the USA, you’d seek a supplier like PHC that can provide optical-grade PET with anti-fog or hard-coat treatments.

Diagnostics & Medical Devices: PET films are also integral in medical diagnostics – for example, as the substrate in lateral flow test strips (the backing card in rapid COVID tests is often white PET), or as cover tapes for reagent arrays. PET is biologically inert and can be made antimony-free (medical grades avoid certain catalysts), which is important for sensitive assays. In medical device manufacturing, polyester films serve as sterilizable packaging (pouches with PET/PE structures) and as protective covers for equipment screens or patient monitors (due to its optical clarity and ability to have anti-microbial coatings applied). Some medical ID cards or licenses use PET layers for durability and security. For instance, a state driver’s license might incorporate a PET holographic overlay that is tamper-resistant. Because PET can be corona or chemically treated, it readily accepts specialized coatings (antimicrobial, hydrophilic for diagnostics, etc.). In summary, in the medical field PET film provides a clean, clear, and stable platform – whether shielding a clinician’s face, enclosing a sterile instrument, or forming the test surface in a diagnostic kit. Its use in U.S. healthcare continues to grow as a safe, reliable plastic film that meets FDA requirements (PHC supplies PET films with FDA/USP Class VI compliance per quoted specs when required).

Industrial Tapes & Release Liners (Silicone-Coated PET, Peel/COF)

Polyester film’s strength and temperature resistance make it a popular backing for industrial tapes and a base for release liners (especially when coated with silicone for easy release).

High-Performance Tape Backings: Many industrial tapes (the likes of splicing tapes, plating tapes, or high-temperature masking tapes) use PET film as the backing material. A polyester tape can be very thin yet hard to break, and it tolerates heat better than vinyl or polypropylene tape. For example, powder-coating masking tape is often a 1–2 mil PET that can endure oven curing temperatures (~400°F) without degrading. PET’s dimensional stability also means the tape won’t shrink or loosen during heating. Electrical tapes, as noted earlier, use PET for dielectric strength. Because PET is naturally smooth, adhesives coat it evenly, and the tape peels off cleanly. Some specialty PET tapes have a matte (high COF) surface on one side to make them easier to handle or to write on, while the other side is adhesive. In summary, wherever a thin but tough tape is needed (often green or amber high-temp tapes you see on circuit boards), PET is likely involved.

Release Liners: Polyester is also used as the substrate for release liners – the slick backing you peel off stickers, labels, or adhesive sheets. A common construction is a 1–5 mil PET film coated with a thin layer of silicone release agent. This silicone-coated PET provides an ultra-smooth, stable liner that resists tearing and can handle die-cutting of intricate adhesive shapes. Unlike paper liners, PET liners don’t absorb moisture or change size, so registration stays accurate (critical for things like electronics adhesives or medical device assembly where liners must peel off cleanly). The PET can be clear or pigmented; sometimes opaque white PET liners are used to make any dust or particles more visible in quality inspection. PHC supplies silicone coated PET release films for label stock and adhesive tape manufacturers – these liners have controlled release levels (easy peel or tighter grip as needed) and come with Certificates of Compliance for consistent silicone coat weight. Additionally, some liner applications require one side with a bit more friction (high COF PET) so that stacked sheets don’t slide; PET liners can be made with one side matte (for grip) and one side silicone (for release), combining both in one film. Overall, polyester-based release liners are valued in U.S. industry because they reduce web breaks at high speed, withstand heat (think of sticking a label on hot surfaces), and leave no fibers or residue. They’re a “clean release” solution that outperforms paper in demanding applications.

Lamination & Cards (ID Cards, Book Covers)

PET films serve as durable laminating layers and card substrates, lending tear-resistance and rigidity to printed materials like ID cards, book covers, and credit card laminates.

Lamination Films: In print finishing, polyester films are widely used to laminate book covers, menus, signage, and other prints that need protection. A clear gloss PET laminating film (often 1.5 mil or 3 mil thick) can be applied over paper to provide water resistance and strength – common in restaurant menus or paperback book covers. PET’s stiffness keeps covers from curling. There are also matte laminating PET films to give a non-glare finish to covers or point-of-sale signs. PET laminating films typically have a heat-activated adhesive on one side (EVA or copolymer) that bonds to the paper when run through a thermal laminator. The result is a very durable composite that won’t tear or delaminate easily. Because PET is so clear, it can enhance color vibrancy of the underlying print. Some specialty laminate films are scuff-resistant PET or have textures (e.g., linen) embossed into the film for aesthetic effect. Compared to cheaper polypropylene laminate, polyester laminate holds up much better over time (no stretching or hazing). It’s the go-to for high-use documents.

ID Cards & Security Laminates: Rigid identification cards (drivers’ licenses, ID badges, access cards) often rely on polyester film layers. In composite card construction, a PET core can be sandwiched between printable faces to add longevity – PET won’t crack as easily as PVC under flexing. Additionally, overlay films that seal the card printing are frequently a hard-coated PET. For example, a 0.5 mil ultra-clear PET overlay may be applied to an ID card to protect the ink and embed holograms. These films have to be extremely clear and scratch-resistant (so the card remains readable after being in a wallet). The U.S. Passport’s polycarbonate page is another example of PET/polycarbonate hybrids where PET film adds flexibility. For large-format laminates (posters, maps), PET sheets provide a durable outer layer that can be written on with markers and wiped (in dry-erase lamination, often a PET film is the outer surface). When customers ask to buy super clear polyester films for ID cards in the USA, they are seeking these optically pure PET laminates that don’t yellow and ensure the card’s information stays intact over years. PHC provides high-clarity graphic grade PET films (see our Matte Polyester Films for Industrial Applications which also covers some durable graphics uses) suitable for laminating and card manufacturing, in custom thicknesses. In summary, PET films in lamination and cards add a tough, transparent armor to printed pieces, combining clarity with strength – essential for items that get handled frequently or must last for years.

Solar/Optical/Displays (Backing, Diffusion, Anti-Glare)

Specialized PET films enable modern solar panels and display systems – serving as reflective or protective backings in solar modules, and as optical films (diffusers, anti-glare surfaces) in screens and lighting.

Solar Panel Backsheets: In photovoltaic (solar) modules, PET films are used as part of the backsheet – the multi-layered plastic sheet that seals the back of the panel. Traditionally, backsheets used Tedlar® (PVF), but today weather-resistant PET films can substitute these fluoropolymers. A typical construction is a white PET layer (for reflectivity) laminated to another PET layer with UV-blocking additives. The white PET reflects light back into the solar cells, boosting efficiency, and it also provides electrical insulation for the module. These backsheet films must survive decades of sun exposure, so they are UV-stabilized PET with special coatings to resist hydrolysis (moisture + heat). PET’s strength keeps the panel intact against mechanical stresses (wind, thermal expansion). Some solar backsheets are now 100% PET constructions (all-polyester), which simplifies recycling compared to mixed-material backsheets. PET is also used in flexible solar panels as the substrate on which solar thin films are deposited, because it can roll and flex while protecting the sensitive photovoltaic material.

Optical & Display Films: Polyester films have numerous optical applications. Diffuser films in LED displays or luminaires are often made from translucent white PET that scatters light uniformly. For example, an LED flat panel light might use a PET diffuser sheet to eliminate hot spots. PET can be loaded with diffusing particles or cavitated (microscopic voids) to create a milky white PET film that transmits light while hiding the LED sources. Conversely, ultra-clear PET is used for things like projector screens or overhead transparencies, where high transparency and low haze are needed. PET’s smoothness allows for anti-reflective or anti-glare coatings to be applied: many anti-glare screen protectors for phones and monitors are PET film with a matte hard-coat that diffuses reflection. This is essentially a matte polyester film for optical displays – it cuts down glare and fingerprints, improving visibility. (Such films are available as affordable, high-quality solutions for device manufacturers in the USA.) Additionally, PET films serve as the base for polarizer films (used in LCDs), after being stretched and iodine-doped (though TAC film is more common for polarizers, some PET variants exist for cost-effective displays). Beam splitter films and reflective films for projectors sometimes use coated PET as well. Lastly, tinted window films (for car or architectural glass) use PET as the carrier because it’s clear and accepts the dye or metal coating that provides the tint and UV blocking. These films must be optically uniform and durable under sun – tasks PET can handle. Overall, from boosting light output in a screen to protecting eyes from glare, polyester films play a behind-the-scenes yet critical role in solar and optical technology.

Film Features & Treatments (What to Choose, When, and Why)

Polyester films can be engineered with special coatings or treatments to impart needed properties – from barrier metallization to heat-seal layers to anti-fog, depending on the application.

Metallized PET

Metallized PET film has an ultra-thin aluminum layer that gives it a shiny foil look and provides exceptional oxygen/light barrier.

A metallized polyester film is essentially PET film that’s been placed in a vacuum chamber and coated with a microscopically thin layer of aluminum. The result is a silvered film that is highly reflective and opaque. This film offers outstanding barrier properties: oxygen transmission can drop to near-zero (OTR in the 0.01–0.1 range)pilcherhamilton.com, and moisture barrier improves dramatically (WVTR often <1)pilcherhamilton.com. Metallized PET is used when you need to extend shelf life or protect contents from light – e.g. snack wrappers, coffee pouches, or pouch structures where it can replace aluminum foil. It also adds an aesthetic: the shiny metallized interior of a chips bag or a holographic label base is metallized PET. Note that metallization adds no thickness but does eliminate transparency, and metallized films cannot be microwaved (they will spark). PHC stocks Metallized PET films in various gauges for packaging and labels, including high metal bond strength grades for robust lamination.

PVDC-Coated PET

PVDC-coated PET has a clear coating of polyvinylidene chloride that dramatically boosts barrier (esp. oxygen and moisture) while retaining transparency.

PVDC-coated PET is a polyester film with a thin layer of PVDC (a chlorine-containing polymer) on one or both sides. PVDC is an excellent barrier polymer – adding it can drop PET’s oxygen permeability by an order of magnitude (typical OTR ~0.3 cc)pilcherhamilton.com. Moisture barrier also improves (~4–8 g/m² vs 16+ for plain PET)pilcherhamilton.com. Unlike metallization, PVDC coatings maintain film transparency, enabling visual inspection of contents and high-quality printing. PVDC also offers excellent heat-sealability with low seal initiation temperatures (around 220 °F/104 °C) and broad seal windows. However, PVDC may discolor over time at high temperatures and is sensitive to moisture during storage; barrier declines when the coating absorbs water. Still, it’s popular for pharma and medical packaging requiring a combination of clarity and barrier. PHC offers PVDC-coated PET films as part of our high-barrier lineup when transparency with barrier is needed.

Clear High-Barrier PET

“Clear barrier” PET refers to films with transparent coatings (like AlOx or SiOx ceramic, or special polymers) that give near-metallized barrier performance while staying see-through.

This category overlaps with PVDC PET but also includes newer ceramic-coated PET films. For instance, an AlOx-coated PET has a thin transparent aluminum oxide layer – these films can achieve very low oxygen transmission (OTR <0.1) while remaining clear. They are often used for “window” pouches where only a portion is clear barrier. Similarly, silicon oxide (SiOx) coatings on PET provide a glass-like clear barrier. The advantage is visibility of the product (say, dried food or coffee beans) without a big compromise in shelf life. Clear high-barrier films are also not electrically conductive (unlike metallized), which can matter for microwaveable packages or metal detector usage. Many of these coatings are applied at the film manufacturing stage and add minimal thickness. They can be a bit more expensive than metallized or PVDC, but the value is in combining barrier + transparency. Use cases include clear retort pouches, certain medical packaging (seeing the device or pill through the pouch), and any packaging where marketing wants a “window” but the product still needs protection. When deciding metallized vs. clear-barrier, consider if showing the product is essential. PHC can supply clear high-barrier PET options (like AlOx-coated PET) on request and will confirm oxygen/moisture barrier specs per quoted film.

Heat‑Sealable PET

Heat-sealable PET film has a coextruded or coated layer (often a copolyester) that melts at lower temperatures, allowing the PET film to seal like a lidding or pouch material.

Standard PET film doesn’t heat-seal to itself because its melting point is high (~250°C). Heat-sealable PET solves that by adding a thin seal layer: typically a PET copolymer or EVA that melts around 100–120°C. This way, the film can form seals on packaging machines (HFFS/VFFS) without needing a separate sealant film. For example, a salad container lid might be a heat-seal PET lid that seals to a tray at 250°F. Some heat-seal PET films are designed to peel easily (used for peel-off lids on food trays – these are called peelable PET lidding). The seal layer is usually clear and may be one-side only (so the outside of the film remains non-tacky and printable). Coated heat sealable PET films are recommended when you want the strength of PET but need to replace a multi-layer structure with a single film that both seals and provides barrier or strength. PHC provides heat-seal PET in various seal-strength levels (permanent or peelable) and will ensure FDA compliance for food use per spec.

Acrylic-Coated PET

Acrylic-coated PET has a thin acrylic polymer coating on one or both sides, imparting a printable, scratch-resistant surface with improved moisture and UV resistance.

An acrylic-coated polyester film typically uses an acrylic resin (like polymethyl methacrylate-based) coated onto PET. This clear coating serves multiple purposes: it primes the surface for excellent ink adhesion (important for graphic films and packaging), it adds UV resistance (acrylic is UV-stable, protecting the underlying PET from yellowing), and it can enhance moisture barrier slightly. Acrylic-coated PET films are widely used for labels and graphics where you want a durable printable surface out-of-the-box (no corona treatment needed at press). They also have a nice gloss and can be slip-modified as needed. For example, many thin label films or tamper-evident films have one side acrylic coated. Another use is in laminations – the acrylic layer can promote adhesion to inks or adhesives. The coating is usually very thin (like 0.5 microns) but makes a big difference in performance. It doesn’t significantly affect transparency. PHC offers Acrylic-coated PET films for customers who need a “print ready” PET or an extra durable surface.

Copolymer-Coated PET

Copolymer-coated PET is PET film with a special polyester copolymer coating that improves adhesion to other layers or provides a heat-seal functionality, often without losing clarity.

This is a bit of a broad category – copolymer-coated PET generally means the film is coated with an altered polyester resin (for instance, an amorphous PET or PETG-based coating). The purpose is typically to enable better bonding in laminates or to give heat seal properties while keeping the film clear. One common example: PET coated with a copolyester that seals to itself or to trays, used in lidding films. Another example is a copolymer coating designed to grab adhesives or inks, acting like a primer that’s more aggressive than standard PET surface. These coatings are engineered to be compatible with both the PET and whatever you’re sticking the PET to (like another plastic). The benefit of using a copolymer coated PET instead of an adhesive layer is it can be thinner and more uniform. It’s often used in multilayer packaging where a PET layer needs to bond to polyethylene or foil – a copolymer tie-layer can be coated onto PET to promote that bond. Copolymer coatings can also add gas barrier or other attributes. In summary, think of copolymer-coated PET as “PET with an extra, compatible skin” to help it stick or seal as needed. It tends to remain clear and doesn’t add much thickness. PHC can supply Copolymer-coated PET films tailored for tricky laminations or specific seal needs.

Corona-Treated PET

Corona-treated PET has been exposed to a high-voltage corona discharge, raising its surface energy to improve adhesion of inks, coatings, and adhesives.

Corona treatment is a post-process where PET film passes under an electrical discharge. This “zaps” the surface, introducing polar groups that make it more receptive to liquids. Fresh PET typically has low surface energy (~42 dynes/cm), which can cause inks or adhesives to bead up. Corona treatment can raise that to ~50+ dynes/cm, which is ideal for printing and coating. The treatment is usually done in-line during film production and can be one or both sides. Corona-treated PET is essential for applications like packaging film that will be printed by flexography or rotogravure, or for tape base film that needs to anchor silicone coatings. One consideration: corona effects can diminish over time or with exposure to contaminants, so it’s best to use corona-treated film within a few months or have it primed for longevity. Corona treatment does not leave a visible change, and it doesn’t affect mechanical properties. It’s simply a surface activation. PHC supplies Corona-treated PET films routinely for customers who do their own printing or adhesive coating, ensuring strong bonds without the need for an added primer coating.

Anti‑Fog PET

Anti-fog PET film has a specialty coating that prevents water droplets from condensing as fog, instead causing a clear, uniform water layer for visibility.

When cold or hot products are packaged, moisture can condense on the film inner surface. Anti-fog PET solves this by using a hydrophilic coating that spreads the water. Instead of tiny droplets (fog) scattering light, the water forms a thin clear film. This is crucial for salad packaging, hot food covers, or face shields – anywhere you need clarity despite moisture. The anti-fog coating is often applied to one side of a PET sheet or roll. It’s common on PET lid films for produce, bakery items, etc., so consumers can still see the food after it’s refrigerated. In face shields, anti-fog coated PET ensures that the user’s breath won’t fog up their visor. These coatings are usually food-safe and can be combined with anti-stat functionality. Anti-fog PET might have a slightly coated look (sometimes a slight haze), but high-quality ones remain quite clear. The coating can be durable, lasting through temperature swings and multiple condensation cycles. PHC can provide PET films with anti-fog coatings tailored to chilled food packaging or PPE applications, so U.S. producers can deliver clear products from factory to consumer.

Anti‑Static PET

Anti-static PET film has been treated or formulated to dissipate static electricity, protecting sensitive electronics and preventing dust attraction.

Plain PET can accumulate static charge (it’s an electrical insulator). Anti-static PET includes additives or surface treatments that allow charges to dissipate. This is critical for packaging electronics components – an electrostatic discharge (ESD) can fry a microchip. An anti-static PET film might be a PET with a topical antistat coating or a PET containing conductive or hygroscopic additives that bleed off charge. Such films typically have a surface resistivity in the range that prevents high static build-up but isn’t outright conductive. They often feel slightly conductive to the touch. Use cases: ESD packaging bags (often PET/foil laminates where the PET layer has anti-stat), tape liners for electronic assembly (so dust doesn’t stick due to static), or protective films for LCD screens during transport (to avoid attracting dust). Another benefit is easier handling on high-speed lines – static can cause films to misfeed or stick; anti-static grades mitigate that. These films usually still look like standard PET (may have a slight surface tint if any). PHC can supply anti-static treated polyester film to clients needing ESD-safe packaging. We ensure that the film’s surface resistivity meets ESD industry guidelines (like <10^12 ohms/sq) per the quoted spec.

UV‑Stabilized PET

UV-stabilized PET contains additives that absorb or inhibit UV light, slowing polymer degradation and preventing yellowing or embrittlement under sun exposure.

While PET is fairly weather-resistant, prolonged UV exposure can cause it to lose tensile strength and color clarity. UV-stabilized PET film incorporates UV absorbers (like benzotriazole derivatives) or HALS (hindered amine light stabilizers) either in the PET or as a coating. These compounds soak up UV rays and protect the polymer chains. The result is a PET film that can last much longer outdoors without turning brittle or hazy. This is essential for applications like outdoor labels/decals, solar panel backsheets, greenhouse films, or any film used in signage. For example, a regular PET label might last a year in sunlight before chalking, whereas a UV-stabilized PET label could last several years. These films might have a slight tint (some UV absorbers are pale yellow), but many are virtually transparent. They maintain other properties of PET while extending service life in sun. If a project calls for polyester film in outdoor conditions, PHC will recommend a UV-stabilized grade or apply a UV-protective coating. It’s part of ensuring the film performs over time in the U.S. climate extremes from Arizona sun to Florida humidity.

One‑Side Matte / One‑Side Gloss PET

One-side matte, one-side gloss PET has differing textures on each surface – one face is finely roughened (matte) to diffuse light, while the other remains shiny.

This type of film is produced by casting one side against a matte roll or adding fillers that create surface texture on one side only. The dual finish is useful because you get two functionalities: the matte side can be used if you need a writable or low-glare surface, while the gloss side can go against a product for a smooth appearance. Label printers might use such film to allow printing on the matte side (reducing glare under retail lighting) but still have a glossy adhesive side for clarity on the bottle. In industrial laminates, one-side matte PET can help eliminate Newton’s rings or air bubbles when overlaying on glass or screens (the matte face prevents interference patterns). Another benefit is that the matte side can be slightly higher friction (grippy) and the gloss side slick, which is sometimes needed in feeders or stacking. Essentially, one film offers two surface options. PHC can provide PET films that are matte/gloss combination, often called “semi-matte” films. They are often found in applications like lidding (matte outside for no glare, glossy food-contact side) or in graphic arts where selective finish is desired without an extra coating step.

High COF / Low‑Slip PET

High COF (coefficient of friction) PET is formulated to be less slippery, ensuring better grip and control in high-speed processing or stacking (low-slip means it doesn’t slide easily).

Standard PET film, especially if very smooth or slip-treated, can have a low COF (very slick). In some machinery, that’s bad – the film might not grip drive rollers or could cause a stack to fan out. High COF PET film is made by avoiding slip additives or by lightly texturing the surface to increase friction. Essentially, it’s a low-slip PET so that it holds its place. One example use: labels that are auto-applied at high speed might use a low-slip backing to prevent the web from slipping on the applicator drum. Another: sheets of polyester used as spacers or interleaves where you don’t want them sliding apart. By contrast, many packaging films are intentionally low COF (slick) to run well; but if you need the opposite, a special grade is required. PHC supplies High COF/Low Slip PET films which have controlled COF values (e.g., a COF of 0.5–0.7 instead of 0.2). We might recommend these for customers who experienced film slippage issues or when layering films and needing them to stay put. High COF PET can also help in pouch making when stacking pouches or in printing when feeding individual sheets. It’s a niche property but one we accommodate for smooth production in U.S. plants.

Clarity Options: Ultra‑Clear, Opaque, Translucent, Hazy

PET films can be made in various clarity levels – from ultra-clear (glass-like transparency) to opaque (solid white or black), with translucent or hazy intermediate options in between for diffused appearance.

Ultra-clear PET: This refers to polyester film with exceptional optical clarity – very low haze (often <1%) and high gloss. These films are used when maximum see-through quality is needed, such as overlay windows, ID card laminates, or display screens. They are often specially purified and smooth surfaced so that they are virtually invisible when applied. (Many consumer touchscreen protectors are ultra-clear PET.)

Opaque white PET: Opaque PET film is loaded with white pigment (typically titanium dioxide) to the point of zero transparency. It provides a solid white look, excellent for blocking light and providing a background for printing (common in labels and medical packaging to hide contents). Opaque white PET reflects light (if used in solar or lighting) and can serve as a “printable white plastic” replacing paper in some applications.

Translucent (Milky) PET: Between clear and opaque is translucent or milky white PET. These films let light through but diffuse it. They often appear cloudy or like frosted glass. This effect is achieved by internal voids or added fillers that scatter light. Translucent PET is used for light diffusion (e.g., in displays or lightboxes as mentioned) and also for aesthetic packaging where you want to obscure the product slightly but still hint at it (some cosmetic pouches use a frosted PET look). Translucent white PET typically has moderate haze (e.g., 50% haze) which gives it that diffused quality. PHC offers Translucent white PET for clients needing this diffusive property.

Hazy PET: “Hazy” usually refers to clear PET that isn’t optical grade – it has some haze value, perhaps 5–20%, due to slight surface texture or minor crystallinity. It’s not intentionally translucent like milky film, but it’s also not ultra-clear. Some PET films come out with a natural haze (especially thicker gauges). In some cases, a little haze is acceptable or even useful (reducing glare or making text on the opposite side easier to read). For instance, a hazy PET might be used for a booklet page insert where full transparency isn’t needed. Haze can also be introduced by matte coatings. Essentially, if an application doesn’t demand crystal clarity, using a standard hazy PET can be more cost-effective than a premium ultra-clear grade. PHC can guide buyers on choosing a PET film with the right clarity level – whether you need it super clear for a window, or a moderate haze is okay (and perhaps beneficial for your use). We always confirm specs like % haze and % transmission on request so you get the appearance you expect.

U.S. Sourcing & Lead Times

In the United States, polyester films are available both as off-the-shelf rolls and custom-converted orders. Stocked PET films can often ship within 24–48 hours, while custom specs take longer. Smart sourcing means using domestic suppliers who meet quality, compliance, and sustainability criteria.

Stock vs. Custom (Fast Shipping)

Major U.S. PET film suppliers keep popular grades in inventory for immediate dispatch (1–2 days), whereas custom sizes or coatings may require lead times of a few weeks.

If you need PET film quickly, choose a supplier with a broad stock inventory. Pilcher Hamilton, for instance, maintains over 3 million lbs of assorted polyester films ready to ship. Common thicknesses (like 48 ga, 92 ga) in standard types (clear, matte, white, metallized, etc.) are often stocked. Such items typically ship within 24–48 hours of order, with nationwide delivery via freight. This means a packaging line in California can reorder and receive film from PHC’s South Carolina hub in a few days.

Custom orders – say you need an unusual width, a special coating, or a very high volume not on the floor – will have a longer lead time. Converting (slitting to a custom width or sheeting) might add a few days or a week. If the film itself must be produced or imported, lead time can be 4–6+ weeks depending on manufacturing schedules or overseas transit. However, a good U.S. distributor will often offer a sample program or trial rolls so you can test a film while waiting for the bulk order. Also, many suppliers will accommodate blanket orders with scheduled releases, so you effectively have rolling stock ready (they hold inventory and ship to you just-in-time). For instance, PHC offers sample rolls and also allows customers to reserve stock under contract for immediate call-off. In general, U.S. buyers benefit from domestic warehousing – you avoid the unpredictability of international shipping and can get your PET film on-site fast when it’s a stock item.

Vetting a Supplier (Certifications & Quality)

To find a reliable PET film supplier, U.S. buyers should verify the company’s quality certifications, material traceability, regulatory compliance, and sustainability initiatives, ensuring they can meet project requirements.

When evaluating American polyester film suppliers, consider the following:

• Experience & Reputation: How long have they been in business? (PHC, for example, was founded in 1904 – over a century of continuous operation, which signals stability and expertise.) Check if they specialize in films; a focused converter likely has better process control.
• Quality Certifications: Look for ISO 9001 or similar quality management certifications. These indicate formalized processes and continuous improvement. Also, if you need food-grade films, confirm the supplier adheres to FDA cGMP guidelines. PHC provides Certificates of Compliance on request for each lot to verify the film meets the quoted specifications.
• Traceability: The supplier should be able to trace materials by batch/lot. In case of any issue, you want to know that every roll can be traced back to its production batch and raw resin lots. Ask if they maintain lot records and retain samples.
• Technical Support: Do they have engineers or technical staff who understand applications? A good supplier can help recommend the right film or troubleshoot issues (like adhesion problems or converting challenges). For example, PHC offers “Ask an Engineer” support for customers to consult on film choice.
• Compliance & Testing: If your application is regulated (FDA for food, UL for electrical, USP for medical, etc.), ensure the supplier can provide the necessary compliance letters or test data. PHC verifies FDA suitability per quoted spec for food films and can supply documents like FDA 21 CFR compliance statements or UL yellow cards for electrical films.
• Sustainability: U.S. companies increasingly want eco-friendly options. Check if the supplier offers PCR (post-consumer recycled) PET films or participates in recycling programs. PHC, for example, has PCR PET options available and can discuss recyclable all-PET structures for packaging.
• Customer References: When possible, see if the supplier has case studies or can share (de-identified) success stories in your industry. A supplier who regularly serves packaging converters, electronics manufacturers, etc., will be attuned to those needs.

Ultimately, you’re looking for a low-risk partnership. Factors like large on-hand inventory (to buffer supply chain hiccups) and multiple U.S. locations for redundancy (PHC has HQ in Illinois and a large SC campus, plus sales offices in GA, NJ, NC) can further de-risk your supply. Taking time to vet a supplier on these aspects helps ensure you get high-quality PET film consistently and transparently – no unpleasant surprises on spec or delivery.

RFQ Checklist: What to Include

A thorough Request for Quote (RFQ) for PET film should include the application details, required properties (barrier, COF, coatings), intended converting method (printing, sealing), dimensions/quantity, and any compliance needs.

When you request a quote from a film supplier, providing clear info upfront will get you an accurate quote faster. Here’s a handy checklist of what to include:

• End-use Application: Describe what you will use the film for (e.g., “snack food pouch, needs 6-month shelf life” or “outdoor equipment label”). This helps the supplier suggest suitable films.
• Required Properties: List critical properties – Barrier needs (oxygen, moisture requirements, if any), Surface needs (high COF vs low COF, matte vs gloss, clear vs opaque), any coatings (like anti-fog, UV block, release, heat seal). For example, specify if you need high oxygen barrier or if the film must be heat-sealable.
• Dimensions & Format: The thickness (gauge or mil), width of rolls or sheet size, length per roll, core ID (3″ or 6″), etc. If you have a preferred supplier’s product code or spec, include it. The slitting pattern (number of rolls and widths) can affect cost, so be clear on what widths you need.
• Converting Process: Mention how you will convert the film – printing (and what type: flexo, digital?), laminating, die-cutting, heat sealing on a form-fill-seal machine, etc. This informs if you need corona treatment, particular release levels, or if the film must endure certain temps.
• Adhesives/Inks: If the film will be glued or printed, note what kind of inks or adhesives (solvent, UV, water-based) to ensure compatibility. For instance, “will be printed with UV-cure inks” might necessitate a primer coating.
• Regulatory Requirements: Specify any compliance or standards needed: FDA food contact (and which food type or temperature conditions), UL 94 flame rating, RoHS/REACH (for electronics), etc. PHC can then confirm “per quoted spec” that the film meets these needs or select a compliant grade.
• Quantity & Timeline: Estimate how much film you need (e.g., 5,000 lbs now, ongoing 2,000 lbs/month) and when. This affects pricing (volume discounts, whether it’s a one-time buy or repeat business) and whether they have it in stock.
• Delivery Location: So freight can be estimated – e.g., “deliver to Dallas, TX”. And note if you require just-in-time deliveries or have warehousing.

By covering these points, you empower the supplier to offer the right material and a firm quote quickly. It also shows you’re an informed buyer, which encourages a supplier to put their best team on your project. PHC’s team, for instance, often can suggest tweaks (like a slightly thicker but cheaper grade) if we understand the full context. So, don’t hesitate to share details under NDA if needed – it will pay off in getting the best film solution and pricing for your needs.

Pricing & Total Cost of Ownership

Polyester film pricing is influenced by material specs (thickness, coatings, special treatments), order volume, and conversion requirements. Beyond price per pound, buyers should consider the total cost of ownership – a cheaper film that causes waste or downtime can end up costing more.

PET Film Cost Drivers

Key cost drivers for PET film include the base thickness, any specialty coatings or treatments, the quantity ordered, and conversion specifics like custom slitting (which can affect yield and waste).

Several factors determine what you’ll pay for polyester film:

• Thickness & Weight: Thicker films use more raw material, so cost scales with basis weight. For example, a 5 mil film will cost roughly 5× a 1 mil film of the same type (plus possibly a slight premium if it’s a less common gauge). So, don’t over-spec thickness if you don’t need it – thinner high-strength PET often suffices, saving cost.
• Coatings & Treatments: Additional features add cost. A plain clear PET is cheaper than one that is metallized or coated with PVDC or acrylic. Each coating step adds manufacturing cost. Similarly, specialty treatments like anti-static or anti-fog involve extra materials and processing. As a rough idea, a metallized PET might cost 20–30% more than an equivalent plain PET; a PVDC high-barrier film can be even pricier. However, these costs may be justified by performance (extended shelf life, etc.).
• Order Quantity: Buying in bulk generally reduces unit cost. Suppliers often have price breaks at certain poundage or roll counts. A full pallet or truckload rate will be better per pound than a one-carton order. But keep in mind storage and shelf-life of treated films (some coatings have a shelf life). PHC and others offer wholesale pricing for high volume – this is ideal for converters who can forecast usage.
• Slitting Pattern & Yield: How you need the film cut can influence cost due to waste. If you require unusual roll widths that don’t nest efficiently from a jumbo roll, the supplier might have to scrap more material and will factor that in. For instance, if a master roll is 60″ wide and you want 3″ rolls, that’s perfect (20 rolls, zero waste). But if you wanted 17″ rolls out of 60″, each cut might leave some trim waste, raising effective cost per usable inch. Providing flexibility on roll width or accepting standard widths can save money.
• Special Handling: Any extra services – extremely precise tolerances, cleanliness (clean-room processed film for medical), custom packaging (like interleaving between sheets), or expedited shipping – can add to cost. If you need certification (FDA, MIL spec testing, etc.), there might be charges for documentation or testing as well.
• Market Conditions & Resin Prices: PET film prices can fluctuate with raw PET resin costs (which are tied to oil prices and supply/demand). In recent years, logistics and global demand also impacted film prices. A U.S. supplier’s prices may include tariffs or duties if the film is imported. Long-term contracts can sometimes lock pricing or provide stability.

Ultimately, it’s wise to communicate which attributes are “must-haves” and which are flexible. Sometimes a slightly different spec (thickness or coating) could be significantly cheaper if it aligns with the supplier’s stock or master roll sizes. A reputable supplier will work with you to optimize these factors for cost-efficiency.

When “Cheap” Gets Expensive

Beware of selecting PET films on price alone – a low-grade or unsuitable film can cause higher costs in the form of machine downtime, waste from poor quality, rejected product, or even liability issues if it fails in use.

It’s tempting to source the cheapest film that meets basic specs, but the total cost of ownership can be higher if that film performs poorly. For example, a bargain PET film that has inconsistent thickness might jam your packaging machine or lead to seal failures – each jam could mean downtime, maintenance, and scrap product that eat into any cost savings. Likewise, lower purity films might have gel spots or blemishes that cause defects in printing (leading to rejects and reprints). If you’re making, say, an LCD diffuser and you use a cheap hazy PET that isn’t uniform, you could end up scrapping whole batches of product due to optical defects.

Another hidden cost is customer returns or complaints. If a cheaper film doesn’t hold up (imagine labels fading or falling off because the film wasn’t UV stabilized, or pouches leaking because the seal layer was inferior), you could face returns, brand damage, and even regulatory issues. The cost of a recall or replacing product can dwarf the savings from buying the cheaper film.

There’s also an efficiency factor: high-quality PET films are engineered for smooth runability. They have consistent winding tension, no blocking, proper slip – so your lines can run at full speed. A low-cost supplier might deliver film that seems fine but perhaps has excessive coefficient of friction variations or poor edge quality, causing you to slow down your machines or constantly adjust. Over time, those lost productivity hours are costly.

Finally, consider that reputable suppliers often include added value in the price – reliable technical support, assured spec compliance, and accountability. If something goes wrong with a higher-end supplier’s film, they will work with you to fix it. With a cut-rate supplier (especially overseas brokers), you might be on your own. As the saying goes, “you get what you pay for.” The key is to find an optimized solution – not overpay for unnecessary spec, but also not undercut critical quality. A good supplier like PHC helps find that balance, preventing those “cheap becomes expensive” scenarios by ensuring the film consistently works for your process and product.

Case Notes: Real‑World PET Film Solutions

A couple of brief examples (with identifying details removed) show how specific polyester film choices addressed customer challenges in packaging and electronics.

Snack Pack Shelf‑Life Boost (Metallized PET)

A U.S. snack manufacturer extended their product’s shelf life and improved packaging appeal by switching from clear poly to metallized PET film.

The challenge: A snack company was finding that their granola clusters were going stale and losing flavor months before the intended 9-month shelf life. They were using a transparent OPP/PE pouch. Oxygen was ingressing, and the product also got light-exposed (leading to nutrient loss). The marketing team liked a window on the package, but the product quality was suffering.

Solution: Working with PHC, they trialed a metallized PET layer in the laminate. By incorporating a 48 ga metallized PET (OTR <0.1)pilcherhamilton.com as the core barrier layer, the new pouch dramatically reduced oxygen ingress. They kept a small clear window by using a stripe of AlOx-coated PET in one section (for a compromise of visibility). After transitioning, the product consistently hit 9+ months shelf life with no staleness. Additionally, the shiny metallized interior gave the packaging a premium look and improved the burst strength of the pouch (fewer leaks). The customer was initially concerned about cost, but the cost per pouch only rose by ~2%, while returns due to staleness dropped to effectively zero – a big win in total cost. This case highlights that choosing a high-barrier PET film can solve shelf-life problems and even enhance branding. (See our dedicated post on Metallized Polyester Films for Snack Packaging Excellence for more insights.)

Electronics Insulation Reliability (BOPET)

An electric motor OEM improved insulation longevity by replacing paper and acetate barriers with BOPET polyester film, eliminating failures in high-heat conditions.

The challenge: A motor manufacturer had been using fish-paper (vulcanized fiber) and acetate sheets to insulate motor windings. Over time (a year or two of operation), some motors were failing due to insulation breakdown – the materials became brittle from heat and absorbed moisture. They needed an insulating film that could last 10+ years in a hot, sometimes humid environment.

Solution: PHC recommended switching to a BOPET polyester film (equivalent to Mylar® Type HT). This film is UL-rated for 155°C (Class F) and has minimal moisture uptake. The OEM trialed a 5 mil PET film as slot liners and phase insulation in their motor. The polyester film proved easy to form and insert (it held shape better than paper) and did not crack under stress. After accelerated life testing, the motors with PET insulation showed no electrical breakdown, whereas the old material had begun to carbonize. The change improved reliability so much that the OEM extended their warranty period confidently. Cost-wise, the PET film was slightly more per square foot than paper, but it eliminated rework and field failures (saving tens of thousands of dollars). This real-life example shows how investing in quality PET film for electrical insulation yields long-term payback. For more on how PET (BOPET) is transforming electronics, check out How BOPET Films Are Revolutionizing Electronics.

Why PHC (Founded 1904): Risk‑Reduced U.S. Supply

Pilcher Hamilton Company (PHC) has over a century of experience in films and offers U.S. buyers a low-risk, high-service partnership – combining huge ready inventory with custom converting, fast shipping, and stringent quality assurance.

PHC isn’t just another supplier – we aim to be an extension of your team, de-risking your supply chain. Here’s why many American packaging and industrial companies choose PHC for polyester films:

• Proven History: Established in 1904, PHC brings 120+ years of materials expertise. We’ve weathered industry changes and continually innovated, so you can trust our stability and know-how. Few others in this niche can claim such tenure.
• Massive Inventory & Quick Delivery: We stock over 3 million pounds of PET and nylon films across common grades. That means stocked items typically ship within 24–48 hours, getting film to your dock fast when you need it. With a major distribution center in Greer, SC and other stocking points, we cover nationwide delivery efficiently. Rush needs or blanket order releases are handled with equal agility.
• Full Converting Capabilities: PHC is not just a reseller – we are a film converter with extensive in-house capabilities. We slit to your exact roll widths, sheet or die-cut films to size, rewind to custom lengths, coat films (silicone, acrylic, copolymer, etc.), laminate films together, and even print on films (up to 8-color flexographic). High-volume or custom jobs, we support them. Having these services under one roof saves you lead time and ensures consistent quality from raw film to finished format.
• Quality & Compliance: Our processes are ISO-aligned and customer-audited. We provide Certificates of Compliance with shipments upon request, verifying that the film delivered meets all specified properties. If your film needs to be FDA compliant for food contact or UL rated for electrical use, PHC confirms compliance per quoted spec and supplies the documentation. Traceability is built into our system – every roll can be traced back to its lot. We stand behind the product; if something isn’t right, we make it right.
• Technical Guidance: Need help choosing the best PET film? Our technical sales engineers are a phone call away. We frequently consult on material selection, whether it’s recommending a high clarity graphic grade for a label or a heat-seal PET for a new lidding project. Customers can Ask our Engineering team for guidance on matching films to application, printing, sealing, etc., at no extra charge. We believe in being helpful first, not just pushing what’s on the shelf.
• Sustainability Options: PHC actively supports greener initiatives. We offer PCR (post-consumer recycled) PET films for those aiming to incorporate recycled content. We can also advise on mono-material PET laminates to improve recyclability of packaging (for instance, all-PET structures). Internally, we optimize yields to minimize waste and participate in recycling scrap. Partnering with PHC can help you meet your sustainability goals without compromising performance.
• U.S. Focused, Globally Connected: We are an American company headquartered in Willowbrook, Illinois, with our main operations in South Carolina and regional sales offices in Georgia, New Jersey, and North Carolina. We understand U.S. regulations, logistics, and market needs. At the same time, we maintain relationships with top global film manufacturers (Asia, Europe) to source specialty films when needed – so you get the best of both worlds: domestic reliability with global reach.

In short, PHC aims to be the low-risk choice for PET films in the USA. We have the stock, the speed, the capabilities, and the commitment to quality that let you focus on your business, not on worrying about film supply. As our long-term clients can attest, we make sure “film” is one thing you don’t have to worry about.

FAQs

Q: What is PVDC-coated PET?

A: PVDC-coated PET is polyester film with a thin layer of PVDC, giving it a very high moisture and oxygen barrier – excellent for food or medical packaging that needs extended shelf life.

Q: What is Clear high-barrier PET?

A: Clear high-barrier PET refers to PET film that maintains transparency while providing strong barrier properties (often via special coatings like PVDC or ceramic) – ideal where a package “window” is needed without sacrificing shelf life.

Q: What is Heat-sealable PET?

A: Heat-sealable PET is PET film designed to form secure seals (for lidding, pouches, etc.) – it has a heat-activating layer so it can be sealed at normal packaging temperatures, preventing leaks and preserving freshness.

Q: What is High COF / Low-slip PET?

A: High COF (low-slip) PET is a film made to be less slippery, which improves stability and control on high-speed equipment (it won’t slide around as easily due to a higher coefficient of friction).

Q: What is Corona-treated PET?

A: Corona-treated PET is polyester film that’s been exposed to an electrical discharge to raise its surface energy – this makes inks, adhesives, and coatings adhere much better (critical for quality printing or laminating).

Q: What is Acrylic-coated PET?

A: Acrylic-coated PET is polyester film with a thin acrylic layer on one or both sides, providing a durable, receptive surface for printing and enhancing moisture, chemical, and UV resistance.

Q: What is Copolymer-coated PET?

A: Copolymer-coated PET has a special polyester-based coating that improves adhesion or barrier without sacrificing clarity – it’s engineered for multilayer packaging, acting like a built-in tie-layer or seal layer.

Q: What is Anti-fog PET?

A: Anti-fog PET is film treated to prevent condensation from forming visible droplets – perfect for cold food packaging or face shields where you need clear visibility despite moisture.

Q: What is Anti-static PET?

A: Anti-static PET is PET film designed to minimize static buildup – it’s used for ESD-safe packaging of electronics and in cleanroom settings to avoid dust attraction and electrostatic discharge.

Q: What is Ultra-clear PET?

A: Ultra-clear PET is a PET film with exceptional optical clarity (very low haze and high gloss). It offers a nearly glass-like transparency and often a scratch-resistant surface for things like display windows and overlays.

Q: What is Opaque white PET?

A: Opaque white PET is PET film that is pigmented to be fully white and non-translucent, providing light-blocking and a solid background for graphics or product protection from light.

Q: What is Translucent white PET?

A: Translucent white PET is a semi-opaque, milky PET film that diffuses light while still masking contents. It’s used when you want light to pass through but hide details (like backlit displays or frosted packaging).

Q: What is Hazy PET?

A: Hazy PET is PET film with a moderate level of haze (not fully clear). It provides a diffused, slightly cloudy appearance for specific visual or functional needs (used when a little light diffusion is beneficial or absolute clarity isn’t needed).

Q: What is Shrinkable PET?

A: Shrinkable PET is a polyester film formulated to shrink when heated (similar to shrink sleeve material). It’s used for shrink-wraps and tamper-evident bands, conforming tightly around products when heat is applied.

Q: What is Twistable PET (clear)?

A: Twistable PET is a PET film made to twist and hold that twist (like candy wrapper ends). It has high twist retention and gloss, making it perfect for confectionery wraps and decorative twist ties.

Q: How can I find suppliers of high-quality coated PET films for face shields in the USA?

A: Look for U.S.-based film converters with medical-grade coating expertise. Many American suppliers (like PHC) offer coated PET for face shields with anti-fog and optical clarity, and can ship nationwide.

Q: Where can I buy coated heat-sealable PET films in the United States?

A: Through specialized polyester film suppliers – ideally those with in-house coating. In the U.S., companies like PHC provide heat-sealable PET films (with seal layers pre-coated) and can deliver quickly from domestic stock.

Q: What polyester film is recommended for high-quality labels in the USA?

A: For labels, a graphic-grade PET is best – typically an ultra-clear or white PET with a print-friendly treatment (corona or acrylic). U.S. suppliers such as PHC carry label-grade polyester films that ensure excellent printability and durability for American label converters.

Q: How do I find suppliers of metallized polyester films?

A: Check for packaging film specialists that advertise high-barrier films. Metallized PET is common, so many suppliers stock it – in the USA, PHC and other converters offer metallized polyester films and can advise on the right grade for snacks or other products.

Q: Where can I get PET films for food packaging in the USA?

A: From American plastic film distributors or direct from a converter like PHC. Make sure they offer food-grade PET (FDA compliant). PHC, for example, supplies PET films suitable for food packaging (including clear, metallized, and sealable types) with quick nationwide shipping.

Q: Do you ship nationwide?

A: Yes—PHC coordinates U.S. shipments from the Greer, SC distribution center and other stocking points, delivering nationwide.

Q: How fast can PHC fulfill orders?

A: Stocked items typically ship in 24–48 hours. We prioritize quick turnaround, so your in-stock films leave within 1–2 business days.

Q: Does PHC offer sustainable options?

A: Yes—PCR PET options available.

Q: Can PHC provide Certificates of Compliance?

A: Absolutely—upon request we provide CoC’s for your order, certifying the film meets the quoted spec and including lot traceability details.

Q: Which industries does PHC serve?

A: We serve a range of industries: primarily packaging, labels & graphics, electrical/electronics, and industrial markets (among others).

Q: What are PHC’s core strengths?

A: PHC prides itself on supreme quality, elevated service levels, creativity in problem-solving, and expeditious delivery to keep your operations running smoothly.

Q: How much inventory does PHC carry?

A: We maintain over 3 million pounds of film on hand to support fast turns and large orders without delay.

Q: Where is PHC based?

A: Our headquarters is in Willowbrook, Illinois, and we operate a major distribution and manufacturing campus in Greer, South Carolina, with sales offices in GA, NJ, and NC.

Q: Can PHC help me choose the right film?

A: Yes—our team will gladly consult. Share your application details (product, packaging format, sealing method, printing process, barrier needs, sustainability targets) and we’ll recommend the best film options.

Q: Are FDA-suitable grades available?

A: Yes—PHC confirms per quoted spec and provides documentation (FDA-compliance letters, etc. available).

Glossary of PET Film Terms

• BOPET: Acronym for biaxially oriented polyethylene terephthalate, which is the full name for the polyester film we discuss. “Biaxially oriented” means the PET is stretched in two directions for strength and stability.
• COF (Coefficient of Friction): A measure of how slippery a film’s surface is. High COF means more friction (less slippery), low COF means the film is very slick. Important for how films run on equipment or stack.
• Haze: The percentage of light that is diffusely scattered when passing through a film. Low haze = very clear film; high haze = cloudy or translucent film. Used to quantify clarity.
• Corona Treatment: An electrical discharge treatment applied to film surfaces to increase surface energy for better adhesion of inks and adhesives. Corona-treated PET sticks things better.
• PCR (Post-Consumer Recycled): Refers to material (like PET resin) that is recycled from consumer-used products. PCR PET films incorporate recycled polyester content, reducing need for virgin resin.
• PVDC: Short for polyvinylidene chloride, a polymer used as a coating on PET to dramatically improve barrier properties (commonly for food packaging). Example brand: Saran™.
• Copolyester: A polyester resin modified by another monomer, used in coatings or seal layers. In PET film context, “copolyester coating” usually means a PET-like layer that can heat-seal or bond better than standard PET.
• ESD: Stands for electrostatic discharge. In film terms, “ESD-safe” or anti-static films are designed to prevent static electricity build-up that could discharge and damage electronics.
• UL: Underwriters Laboratories, a safety certification body. “UL-rated” polyester films (like UL94 VTM-2 for flame or UL 746 for electrical) have been tested and recognized for specific safety standards, often important for electrical uses.
• Gauge: A film thickness unit (often used in the US). 100 gauge = 1 mil (approx. 0.001 inch). So 48 ga is ~0.48 mil. Also, “gauge” colloquially means thickness in general.
• Mil: A unit of length equal to one thousandth of an inch (0.001″). Used to specify film thickness (e.g., 2 mil = 0.002 inch ≈ 50.8 microns). Not to be confused with mm or millimeter (1 mil = 0.0254 mm).
• OTR: Oxygen Transmission Rate, measured as cc (of oxygen) per area per day. It indicates how much oxygen can pass through a film – lower OTR means better oxygen barrier. Measured under specific conditions (like 23°C, 0% RH).
• WVTR: Water Vapor Transmission Rate, measured as grams (of water vapor) per area per day. It shows how much moisture passes through a film. Lower WVTR = better moisture barrier (often measured at 38°C, 90% RH for packaging films).

Next Steps

Ready to move forward? PHC is here to help U.S. buyers with their polyester film needs.

Request a Quote: If you know what you need (or even if you’re not sure yet), contact PHC for a prompt quote on polyester films. We’ll confirm specifications and provide pricing, lead times, and any technical info you require.

Ask our Engineering Team: Not certain which PET film suits your project? Leverage our 120+ years of expertise – ask an engineer at PHC. We can discuss your application, recommend film candidates, and even send data sheets or samples to guide your decision.

Request Samples: We encourage trialing our films. PHC can supply sample rolls or sheets of many PET film grades so you can test compatibility with your equipment and product. Just let us know what you’d like to evaluate.

Finalize & Partner: When you’re ready, we’ll work with you to finalize the film spec and logistics. Our team will ensure a smooth onboarding – whether it’s setting up blanket orders for steady supply or aligning delivery schedules with your production. With PHC as your polyester film partner, you can proceed confidently, knowing material will be one less worry on your plate.

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Interested in learning more or getting started? Reach out to PHC today to discuss your polyester film needs. We look forward to helping you achieve packaging, labeling, and industrial success with the right PET film solutions.