PVC and polycarbonate (Lexan) overlays look similar at first glance — both are clear, both can be reverse-printed. But over a few years they age very differently, and that difference determines whether your industrial label looks new or scrap after a decade.
📌 What Goes Wrong with PVC
PVC contains plasticisers that migrate to the surface over time, leading to a yellow tint and a sticky residue. Under UV the polymer chains degrade, producing brittleness and stress cracks. Under flame PVC releases chlorine gas — a problem against industrial safety standards.
📌 Why Polycarbonate Wins
Lexan polycarbonate has no plasticiser to migrate. With UV-stable additives it retains optical clarity for 7–10 years outdoors and indefinitely indoors. It survives 100°C continuous and rebounds from sub-zero temperatures.
📌 Side-by-Side Comparison
- UV stability: PVC yellows in 1–2 years. PC retains clarity for 7–10 years outdoor.
- Cold flexibility: PVC stiffens below 0°C. PC remains flexible to -40°C.
- Chemical resistance: PVC degrades under solvents. PC resists alcohols, oils, mild acids.
- Flame behaviour: PVC releases chlorine. PC slows propagation, no toxic gas.
- Print method: Both can be reverse-printed; PC's clarity is superior.
📌 The Bora Ajans Rule
We use only polycarbonate for industrial overlays. PVC has its place — short-life graphics, indoor signage — but never on equipment expected to last a decade. Quality-grade PC costs slightly more, but pays back many times over in service life.
📌 Migration Path from PVC
If you currently use PVC overlays on machinery, switching to PC is straightforward — same overall thickness range, same adhesive options, same printing methods. Send your current artwork and we'll quote a PC equivalent within 24 hours.