Kalpana brings “superspatial ALD” to the packaging industry

A spiral-shaped conveyor system, a rotating deposition head and extremely precise gas control. With these core elements, Kalpana Systems, founded in 2021, aims to transform the traditional batch-based atomic layer deposition (ALD) process into a high-throughput method for flexible substrates. Its roll-to-roll machine applies moisture-resistant metal oxide barriers to these substrates, for example for flexible OLED displays and solar cells.

The machine is designed for integration into existing roll-to-roll production lines. Thanks to a compact design, precise gas separation and high throughput, Kalpana makes ALD attractive for sectors beyond electronics where large-scale production at the lowest possible cost is essential. Because the machine is compatible with flexible substrates and ALD layers are wafer-thin, which makes them insignificant in recycling, the packaging industry is an interesting market for the Delft-based company. This sector manufactures and reuses billions of kilometers of material annually.