Paperboard is coated with plastics to combine the mechanical properties of the paperboard with the barrier and sealing properties of plastics. Paperboard combined with a relatively small number of plastic materials will provide the extra features needed to make the paperboard suitable for a number of specially demanding applications. Extrusion coating is a process whereby molten plastic is applied to paperboard and subsequently chilled to form an extremely thin, smooth layer of uniform thickness.

The molten plastic can be used as an adhesive to laminate a plastic film or a metal foil. Extrusion coating and lamination are used to achieve:

1. moisture protection
2. barrier to water vapour, oxygen, aroma, etc.
3. grease resistance
4. heat sealability
5. sales appeal, for example shiny surfaces.

Sales appeal: The use of extrusion coated and laminated paperboard provides outstanding promotional benefits in terms of visual appeal and consumer handling. High gloss is created by extrusion coating and a specific high gloss chill roll. A metallic effect is created by lamination with aluminium foil or metallised polyester film. These materials and processes also provide tactile sensations of high quality and luxury which the consumer associates with high value products packaged in these materials.

Examples of extruded and laminated products providing sales appeal

1. PE (polyethylene) extrusion coating of paperboard with a gloss or matt finish. Printing and gluing (with cold glue) can be done on a corona-treated surface.
2. PP (polypropylene) and PET (polyethylene terephthalate) are two heat resistant polymers that, applied on the board, can be used in oven applications.
3. Aluminium foil and metallised polyester film may be laminated to the paperboard to provide a metallic effect. Printing can be done on a pre-treated surface.

Functional coating: Paperboard as such is suitable for the packaging of dry products in general.

However, plain paperboard is only suitable for direct contact with moist and greasy foods to a limited extent, because moisture will affect the mechanical properties of the paperboard, and absorbed grease will cause stains. Such effects will obviously reduce the protective function of the package and may detract from the appearance as well. Extrusion coating or lamination adds a thin layer of plastic to the paperboard. Plastic coatings can provide resistance to grease and moisture and, where appropriate, be heat resistant. Plastic coatings can be heat sealed and in some constructions these seals can be leak proof. Depending on the application, the paperboard may be extrusion coated on one or two sides. Aluminium lamination provides packages with a barrier to light, moisture, grease and gases. The aluminium foil is often plastic coated to provide product safety and heat sealing abilities.

Key characteristics: A number of process parameters influence the grammage of the coating.

The most important are:

1. flow of the plastic melt
2. temperature of the plastic melt.

Source of the above information: https://www.iggesund.com/globalassets/iggesund-documents/rm-pdfer/1.-fr…

In today’s world, the brand’s recognition, perception, image and differentiation depends on the packaging of the product.

The packaging and labels can be used by marketers to encourage potential buyers to purchase the product. Package graphic design and physical design have been important and constantly evolving phenomenon for several decades. Marketing communications and graphic design are applied to the surface of the package and the point of sale display.

Packaging is the activity of designing and producing the container or wrapper for the product. It is an important and effective sales tool for encouraging the consumers for buying. It is powerful medium for sales promotion. It must perform all the basic function such as protection, ease of handling and storage, convenience in usage etc. and should not be deceptive and convey any deceptive message. It is the best method for attracting the consumers for buying the products.

According to W. J. Stanton, “Packaging may be defined as the general group of activities in product planning which helps in value designing and producing the container or wrapper for a product.” Let the Packaging speak! is the famous tagline used across packaging fraternity. Ferrero Rocher, for example, is known by the appealing gold wrapper of its brown chocolate. Nestle’s Kit Kat comes in red colour with silver colour wrapping packaging inside. In the culinary world, there's a saying that people eat with their eyes. Beautiful-looking food makes people not only want to consume the food but also to believe that the food actually tastes better. In marketing, this shows that product packaging is ultra important. Having a memorable presentation affects perception, and will keep customers returning again and again.

Thus, it can be genuinely inferred that Packaging and Marketing are the two faces of the same coin.