8,000 m²
Production site in Lingang New Area, Pudong, Shanghai
From laminated web to finished liner
The Induction Seal Liner Manufacturing Process, Step by Step
How induction seal liners are made inside our Shanghai factory: four raw materials are laminated into a continuous web, unwound and registered, rotary die-cut to your diameter, then stripped, counted and packed. Every step of the induction liner production process happens in-house, no stage is outsourced.
Structure recap: Backing · Release Wax · Aluminium foil 20 µm · Heat seal lacquer, the four layers every induction liner is built from.
Explode the four layers →
How induction sealing works →
Drag to look along the line
The process
Five steps from laminated web to finished liner
Raw board and foil go in at one end, counted cartons of finished liners come out at the other. These are the same five steps the 3D line above runs continuously.
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01
Lamination
Pulp backing board, release wax, aluminium foil (20 µm) and heat seal lacquer are laminated into a continuous web, in one pass, with film tension and coating weight controlled per order, so the lot behaves the same on your filling line months later.
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02
Unwind and register
The laminated web is unwound and registered so the rotary die stays aligned to the web. Register eyes lock the print and the die station to the same datum, which is where diameter consistency comes from.
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03
Rotary die cutting
A hardened cylindrical die rolls across the web and shears every liner in the row at once, run after run.
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04
Matrix stripping
The waste matrix, the skeleton between the discs, is stripped away and rewound. It is the only material the process loses, and it never touches the liner face.
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05
Counting and packing
Discs are counted and packed into cartons, ready for cap lining equipment, or rewound on cores for automatic insertion lines.
Choose your structure
One-piece or two-piece, plain or printed, standard or pull-tab, the process above builds them all. Pick the layer build-up that matches your container and contents.
In-house manufacturing · Shanghai
Every step under one roof
Lamination, converting, inspection and packing all happen inside our own plant in Lingang New Area, Pudong, the induction seal liner factory behind every batch we ship. Take the factory tour →
1,000 m²
Class-100,000 cleanroom for hygiene-sensitive fills
150 m²
In-house physics and microbiology laboratory
40+ workers
Production team averaging 10+ years on the line
Built into the line
Quality checks every batch, not every so often
01
Controlled environment
A 1,000 m² Class-100,000 cleanroom for hygiene-sensitive fills, liners for food and personal care are made under controlled conditions.
02
In-house laboratory
Our own 150 m² physics and microbiology laboratory checks every batch before it leaves the plant.
03
Locked formulations
Raw-material lot traceability and locked recipes, the liner you approved is the liner you receive, batch after batch.
Delivery formats
Discs or reels, ready for your lining equipment
Two standard delivery forms come off the same line. Tell us how your caps are lined and we will match the format, the core and the packing to it.
Format 01
Pre-cut discs
Die-cut to your diameter anywhere in the Ø 9–182 mm range, counted and packed in cartons. The standard format for cap lining machines and manual insertion.
Ø 9–182 mm
Counted batches
Format 02
Rewound reels
Punched liners rewound on cores for automatic liner insertion lines, web direction and core size matched to your equipment.
Automatic insertion
Core size matched
| Parameter | Typical range | Notes |
|---|---|---|
| Liner structure | 4 layers | Backing · Release Wax · Aluminium foil · Heat seal lacquerOne-piece and two-piece builds |
| Aluminium foil gauge | 20 µm | Chosen by container size and the barrier your contents need |
Send us your container, we will propose the structure and make your liners on this line.
Free sample liners in your diameter, you cover only the courier cost. Every enquiry answered within 48 hours.
Send Us Your Bottle Specs
winston@zilingpackaging.com
or contact us directly:
WhatsApp +86 183 1708 1689