Printing on cigarette inner liner paper may look straightforward, but anyone who works with metallized or holographic paper knows it’s a delicate process. The metallic surface behaves very differently from normal paper — even a small change in conditions can lead to visible printing defects.
To achieve a premium, consistent finish, it’s important to understand the common challenges in inner liner paper printing and how to prevent them before they affect production.
One of the most frequent problems when printing on metallized inner liner paper is poor ink adhesion. The aluminum layer’s smooth, non-porous surface doesn’t absorb ink like uncoated paper, which can cause smudging, peeling, or uneven color density after drying.
How to avoid it:
Check and control the surface tension of the metallized layer — treat it properly (e.g., corona or primer coating) before printing.
Use ink systems designed for metallized surfaces, such as oxidative or UV-curable inks.
Ensure complete drying and curing before rewinding or lamination.
Because metallized paper reflects light, printed colors can look different from proofs — often duller or slightly off-tone. This is especially noticeable with light or gradient colors.
How to avoid it:
Apply an opaque white or special base coating to reduce reflectivity.
Use color profiles calibrated for metallic substrates with adjusted density settings.
Review press proofs under realistic lighting before full production.
The ultra-smooth surface of metallized paper can lead to slippage on high-speed presses, causing registration errors or blurred patterns, particularly in multicolor gravure or flexo printing.
How to avoid it:
Fine-tune web tension and handling systems to keep paper stable without stretching.
Select a controlled slip coefficient (typically 0.15–0.20) for inner liner paper to ensure smooth yet stable running.
Monitor moisture content, as excessive dryness or humidity can cause dimensional changes.
Curling is a common problem with thin inner liner paper (around 40–50 gsm), especially when moisture or solvent absorption is uneven between coated and uncoated sides.
How to avoid it:
Store paper in climate-controlled conditions to balance moisture before printing.
Use low-solvent inks and control drying temperature.
Add a back coating or perform tension rebalancing after printing if needed.
High-speed printing on metallized paper often generates static electricity, which attracts dust and results in pinholes, spots, or uneven gloss. This is more likely in dry or cold seasons.
How to avoid it:
Maintain 50–60% relative humidity in the pressroom.
Install static eliminators or ionizing bars on printing lines.
Keep the paper surface clean — even minor dust can reduce gloss and color consistency.
After printing, metallized inner liner paper often undergoes lamination or embossing. If inks aren’t fully cured or coatings are incompatible, bubbling, delamination, or dulling may occur.
How to avoid it:
Confirm ink and adhesive compatibility with metallized surfaces.
Allow sufficient curing time before lamination or embossing.
Control lamination pressure and temperature to protect the aluminum layer.
Printing on metallized or holographic inner liner paper requires more than advanced machinery — it demands a deep understanding of the material itself.
By controlling surface treatment, ink formulation, and environmental conditions, printers can achieve sharp, vivid, and stable printing results.
At our company, we collaborate closely with converters and cigarette packaging manufacturers to ensure that our metallized paper performs flawlessly — from printing and lamination to the final pack. Because in cigarette packaging, every detail matters, and the brilliance of the finish begins with the precision of the process.
