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Coatings

Custom Coating Technology for Flexible Packaging

Custom Coatings & Flexible Packaging:
A Combination of Layers & Substrates

custom coatingsCustom coatings are a necessary part of flexible packaging and widely used in today’s world. It is used to package a multitude of products such as fast-foods, coffee, bulk liquids, meats, cheese, spices and more. A mixture of substrates and custom waterbased coatings are combined at various levels to create a barrier protection for products packaging.

A typical package may contain several layers of substrates and coatings. Two typical combinations are demonstrated in the Coating Technology for Flexible Packaging white paper published by TAPPI. Layers consist of various levels of PET. Printed, Adhesive coatings, Primers, Foils and LDPE.  Learn more about standard types of barrier coatings for flexible packaging, how they are applied and the benefits of custom coating formulation.

For a full glossary of custom coating terms  or for more information about aqueous coating solutions contact Roymal, Inc. at roymal@roymalinc.com or by calling (603) 863-2410.

PaperCon 2017 – Minneapolis, MN

PaperCon 2017

PaperCon 2017
April 23-26, 2017
Minneapolis Convention Center
Room: M100D
Minneapolis, MN

Don’t miss the opportunity to be part of the most important gathering of Paper and
Board Professionals in the industry.

PaperCon brings together industry professionals from around the world eager to share knowledge, innovation and new ideas about the paper and board industry.  These professionals know that PaperCon is the premier industry event offering them the opportunity to learn and discuss the latest technologies, best practices, issues and solutions to help them stay competitive in today’s marketplace.

Learn from a panel of experts from TAPPI’s Coating and Graphic Arts Division

This exceptional training in the basics is held as part of the Coating Program at PaperCon 2017, and it’s a great way to kick off all the events taking place in Minneapolis, Minnesota.

The topics covered:

  • Current commercial print methods and the equipment used, including traditional offset and emerging digital technologies
  • Paper and packaging grades that are typically printed and the methods used
  • Examples of print and press problems, how to identify and potential solutions
  • Predicting and testing print quality
  • Color perception and color gamut

Introduction to Printing 101

This two-day introductory course is designed for those who need to understand print quality, attend print trials, trouble shoot print problems or are generally new to printing operations.You’ll learn from a panel of experts from TAPPI’s Coating and Graphic Arts Division.This exceptional training in the basics is held as part of the Coating Program at PaperCon 2017, and it’s a great way to kick off all the events taking place in Minneapolis, Minnesota.The topics covered: Current commercial print methods and the equipment used, including traditional offset and emerging digital technologies.

  • Paper and packaging grades that are typically printed and the methods used
  • Examples of print and press problems, how to identify and potential solutions
  • Predicting and testing print quality
  • Color perception and color gamut

For a complete agenda, registration information and other useful information please visit http://www.papercon.org/attendevents/

 

Converters Expo Celebrates 10 Year Anniversary

Converters Expo has more exhibits and larger booths with the same great event for the converting community!converters expo

Converters Expo is celebrating its 10th anniversary on March 23 at Lambeau Field in Green Bay, Wisconsin, and doing so with intentions of exceeding the record 650 attendees and 100-plus exhibitors that made the show a rousing success in 2016. The one-day expo is expected to host about 20 percent more exhibits this year compared to previous shows, and all exhibitors will have 8-by-10-foot booths instead of tabletops to showcase more products and offerings.

Event organizers anticipate that more than 700 attendees will be in Green Bay this March, browsing more than 120 vendor booths. The exhibitor service categories include coating and laminating, adhesives, flexo printing, inks, slitting/rewinding, film and testing, among others.

Converters Expo is produced by the Packaging Strategies group, along with sister publications and media partners Flexible Packaging and Brand Packaging.

Must-See Products at Converters Expo

Anilox Roll Cleaning Systems (Booth 111): Anilox Roll Cleaning Systems (ARCS) will showcase its new laser system, a proprietary circular scan laser cleaner engineered to clean rolls safely and efficiently on or off press.

Charter NEX (Booth 6): Charter will showcase its line of GreenArrow recyclable films, which either use single materials or materials that allow the films to be recycled. This line includes standalone films, print films for laminations and sealant films for laminations. GreenArrrow films meet the requirements for the How2Recycle “Store Drop-Off” label.

Componex (Booth 34): Componex will be exhibiting and running in-booth presentations of its complete product line of WINertia Idler Rolls. WINertia Idlers are manufactured with patented WINertia tubing, Dynamic Center-WIN Balancing and WINertia Self-Adjusting Bearings to provide customers with free-spinning, low-inertia rollers.

Filmquest (Booth 21): Questar CP-270 and Plystar LP-413 highlight the films that Filmquest will have on hand at the show. The former is a polyester film that’s coated with a proprietary polymer to promote ultra-high bond strength, and then metalized on one side with corona treatment on the opposite side. The Plystar LP-413 is a transparent polyester anti-fog lidding film with one side suitable for peelable seals or rigid substrates used in packaging.

Finzer (Booth 92): Finzer Roller will showcase its backup brushes and customizable web tensioning brushes. Its backup brushes offer an ideal replacement for metal anvil rolls and are designed to offer superior slitting and perforating ability. Its tension brushes work with any film line application, are cost effective, and easy to retrofit and install.

Jemmco (Booth 48): Jemmco will be showcasing its expanded line of JemmTron Corona Treater Roller coverings and accessories, specifically its first conductive corona treater silicone sleeve, the JemmTron CRS100. The sleeve is ideal for use in bare roll and dual-dielectric corona treating systems employing ceramic electrode tubes, as the soft rubber surface helps reduce backside treat and its unique electrical properties help redistribute power to reduce energy waste and improve treat levels.

Meech (Booth 63): Meech will have its enhanced Hyperion 971IPS-30 anti-static system on display. The extra-long range pulsed DC ionizing bar is the most powerful ionizing bar in the Hyperion range, offering an operating working distance of 200 to 1,500 mm.

Pearl Technologies (Booth 67): Pearl is emphasizing the safety and effectiveness of its products at the event in response to customer demand. It will be displaying its Lighting Wicket Punch Safety Enclosure, Pivot Mount Assembly for side rail mount flex units, Remote Spreader Bar and more.

Preco (Booth 8): Preco representatives will be on hand to discuss the company’s line of high-quality, cost-effective laser processing systems for the flexible packaging industry. Its cross web systems allow the converter to move across the web for scoring, shape processing and zone processing, while its web direction systems are utilized for scoring and micro-perforating.

Roll-2-Roll Technologies (Booth 55): Roll-2-Roll Technologies will introduce its WPS 440 IR, its latest in web positioning sensors for the converting and general automation industry.

Simco-Ion (Booth 96): Simco-Ion will have its updated IQ Power Control Station on display. The revamped station now incorporates the latest in ionization technology and a 10-inch, full-color touchscreen with an intuitive user-friendly interface to help monitor and control static-neutralizing systems globally or by device.

Wikoff (Booth 119): Wikoff will have its Compass Ultra White high-performance laminating inks on display, which offer high opacity relative to conventional flexo laminating white inks. Additional benefits include excellent ink transfer, low solvent retention and ideal adhesive laminating bonds, among others.


Converters Expo 2017: What You Need to Know

When: March 23; 9:30 a.m. to 3:30 p.m.
Where: Lambeau Field, 1265 Lombardi Avenue, Green Bay, Wisconsin
What: North America’s largest one-day converting event
More info/registration: www.ConvertersExpo.com


Converters Expo 2017 Agenda

Wednesday, March 22
6 – 7:30 p.m.: Welcome reception at Green Bay Packers Hall of Fame
Thursday, March 23
9:30 a.m. – 3:30 p.m.: Expo open
Noon – 2 p.m.: Lunch buffet
1:30 – 3:30 p.m.: Happy hour on expo floor

Article Published by Eric Fisch, Flexible Packaging Magazine 

Waterbased Coatings Market – Global Industry Analysis

aqueous coating reportsWater-based coatings are a type of coating which use water as a solvent. Water is employed as a dispersal agent for resins to make them eco-friendly and easy to use. Water constitutes more than 75% of the coatings with traces of other solvents like glycol ethers. Rising architectural activities and stringent government regulation related to VOC content are the major drivers that drives the growth of water-based coatings market. Asia Pacific dominates the water-based coatings market in terms of demand. Countries such as China,India are expected to be the key consumers of water-based coatings. Volatility in raw material prices and susceptibility to environmental conditions is anticipated to hamper the market growth.

Acrylic water-based coatings is anticipated to be the major segment during the forecast period, however polyurethane water-based coatings is expected to grow at highest CAGR compare to other resins type. In terms of end-use, building & construction is projected to be the major segment for water-based coatings. Automotive segment is also second most lucrative segment for water-based coatings market. Increasing awareness and stringent government regulations related to VOCs content related to coatings is estimated to offer major opportunities to the water-based coatings market in the next few years.

Global Waterbased Coating Market: Scope of the Study

This report analyzes and forecasts the market for Water-based coatings market at the global and regional level. The market has been forecast based on volume (Kilo tons) and revenue (US$ Mn) from 2016 to 2024, considering 2015 as the base year. The study includes drivers and restraints of the global water-based coatings market. It also covers impact of these drivers and restraints on demand for water-based coatings market during the forecast period. The report also highlights opportunities in the water-based coatings market at the global and regional level.

The report includes detailed value chain analysis, which provides a comprehensive view of the global water-based coatings market. Porter’s Five Forces model for the water-based coatings market has also been included to help understand the competitive landscape in the market. The study encompasses market attractiveness analysis, where in resins and end-users are benchmarked based on their market size, growth rate, and general attractiveness.

Global Waterbased Coating Market: Segmentation

The study provides a decisive view of the global water-based coatings market by segmenting it in terms of resins and end-users. In terms of resins water-based coatings is classified as acrylic, formaldehyde, polyurethane, alkyds, epoxy and others (including fluoro-polymers etc.). Acrylic water-based coatings is further segmented into Styrene acrylic. Further segmentation is based on End-users such as building & construction, automotive, furniture, electronics, marine, paper & printing and others (includes aerospace etc.). Automotive is further segmented into automotive OEM and automotive refinish for analysis. These segments have been analyzed based on present and future trends. Regional segmentation includes current and forecast demand for Water-based coatings in North America, Europe, Asia Pacific, Latin America, and Middle East & Africa.

The report provides the actual market size of water-based coatings for 2015 and estimated market size for 2016 with forecast for the next eight years. The global market of water-based coatings has been provided in terms volume and revenue. Market volume has been defined in Kilo tons and revenue in US$ Mn. Market numbers have been estimated based on resins and end-users of water-based coatings. Market volume and size have been provided in terms of global, regional, and country level markets.

Global Waterbased Coating Market: Research Methodology

In order to compile the research report, we conducted in-depth interviews and discussions with a number of key industry participants and opinion leaders. Primary research represented the bulk of research efforts, supplemented by extensive secondary research. We reviewed key players’ product literature, annual reports, press releases, and relevant documents for competitive analysis and market understanding. Secondary research includes a search of recent trade, technical writing, Internet sources, magazines and statistical data from government websites, trade associations, and agencies. This has proven to be the most reliable, effective, and successful approach for obtaining precise market data, capturing industry participants’ insights, and recognizing business opportunities.

Secondary research sources that are typically referred to include, but are not limited to company websites, annual reports, financial reports, broker reports, investor presentations, SEC filings, European Coatings World, and external proprietary databases, and relevant patent and regulatory databases such as ICIS, Hoover’s, oneSOURCE, Factiva and Bloomberg, national government documents, statistical databases, trade journals, market reports, news articles, press releases, and webcasts specific to companies operating in the market.

We conduct primary interviews on an ongoing basis with industry participants and commentators to validate data and analysis. These help validate and strengthen secondary research findings. These also help develop the analysis team’s expertise and market understanding.

Red the full article here and download the complete industry report. 

NEWS PROVIDED BY Report Buyer, Jan 31, 2017

Waterbased Coatings to Surpass Solvent-based Coatings by 2020

Waterbased Coatings Lead Solvent Based Solutions

Waterbased CoatingsHistorically, solvent-based coatings have maintained the largest share of the protective and specialty coatings market. However, solvent-based coatings are projected to be surpassed by water-based coatings by 2020 as regulatory concerns continue to affect the protective and specialty market. Solvents will continue to lose share to other formulations, with trends favoring the use of aqueous coatings, high-solids, and other coatings, which have lower or no VOC emissions. These and other trends are presented in “Protective & Specialty Coatings Market in the US,” a new study from The Freedonia Group, a Cleveland-based industry research firm.

Waterbased Coating Market on the Rise

Demand for water-based coatings in the protective and specialty segment is predicted to expand at an annual rate of 2.5 percent to 85 million gal. in 2020, supplanting solventborne coatings as the market leader. The trend toward waterborne coatings in the automotive refinish market, which historically has widely used solventborne coatings in an array of applications, is of particular importance for this formulation. End users of automotive refinishes have increasingly adopted waterborne coatings because of their improved color-matching capabilities and faster drying times than their solvent-based counterparts.

Water-based coatings also are gaining a foothold in protective marine coatings as several worldwide treaties and U.S. regulations have put stringent limits on harmful emissions produced by marine coatings. Waterborne coatings provide good adhesion to the market’s primary substrate—metal—and offer solid weatherproof, chemical resistance and tolerance to harsh conditions in which all varieties of watercraft are exposed.

To read the complete report click here.

Published by The Fabricator, January 23, 2017

2017 CoatingsTech Conference

2017 CoatingsTech Conference The 2017 CoatingsTech Conference will be held March 20-22, 2017 at the Westin Cleveland Downtown in Cleveland, Ohio. Sponsored by the American Coatings Association (ACA), the theme of the conference is “Meeting the Sustainability Challenges of Today and Tomorrow.”

The multi-track forum offers industry experts a platform for sharing new research, and will include innovative and advanced short courses, as well as several open forum sessions. David Bem, vice president of Science and Technology and chief technology officer at PPG Industries, will deliver the keynote address on current and emerging market demands and regulatory trends.

Following the keynoter will be sessions on Advanced Analytics and Modeling Strategies; Novel Materials; Smart and Multifunctional Coatings; Weathering and Service Life/Paint Defects; Bio-based Solutions; Industrial Coatings; and Product Stewardship. In addition to technology-focused sessions, the conference will also feature a special one-day Regulatory & Sustainability Session, which will begin with an address from Michael Morris, program supervisor from California’s South Coast Air Quality Management District.

Also offered will be 10 sessions covering topics such as Prop 65, Ozone Transport Commission Initiatives, TSCA, national emissions standards for hazardous air pollutants, and more. The CoatingsTech Conference enables coatings manufacturers, their suppliers, universities, and government representatives to share ideas, collaborate, and gain up-to-date information on topics critical to the coatings industry.

See more at: http://www.coatingsworld.com/contents/view_online-exclusives/2017-01-03/aca-coatingstech-conference-to-be-held-march-20-22-in-cleveland/#sthash.ele4Qw3W.dpuf

Article published by coatingsworld.com

Food Packaging Inks and Coatings: Safety and Compliance

Food Packaging Inks and Coatings

Food packaging inks and coatings compliance tends to cause much confusion and concern for those involved, from the raw material supplier to the printer or coating producer, to the end-use customer. Defined as an ink, overprint, or functional paper and packaging varnish, a wide variety of “coatings” are used on myriad food packages, including ready-to-eat, microwavable, take-out, refrigerated and frozen consumable items. However, there is confusion about the difference between direct and indirect contact versus direct and indirect additives, how specific applications are addressed in the regulations, and what options are available when establishing suitable safety and regulatory clearance for food packaging. In this article, we will discuss the applicable regulations and other considerations for determining the suitability of a coating for use in a food contact application.

When is a Coating a Food Additive?
A food additive is defined in the FFDCA as “…any substance the intended use of which results or may reasonably be expected to result, directly or indirectly, in its becoming a component of, or otherwise affecting the characteristic of any food including any substance intended for use in…packing…packaging…or holding food….” Based on this definition, under many circumstances printing inks and coatings that come into contact with food are considered food additives, and are therefore subject to premarket clearance by FDA. Two types of food additives recognized by FDA are direct additives and indirect additives. Direct additives are substances that are intended to become ingredients in a food product and therefore, are intended to be eaten. These include preservatives, flavoring agents, gums and anti-caking agents. Indirect additives are substances used in the processing, packaging, holding and transporting of food. These additives have no functional effect in the food, but may be reasonably expected to become components of food or to affect the characteristics of food. Inks and coatings often fit within this portion of the food additive definition.

In addition, the FDA recognizes three types of food contact. Direct Contact substances are those that directly contact food. Substances that might come in contact with food, such as on the outside of food bag or carton, are defined as indirect contact. Finally, incidental contact substances are those that rarely contact food and the contact is not purposeful or continuous. For example, food that contacts an extraneous part of a food processing machine where contact is not expected is considered incidental.

There often is confusion with the terms “direct additive” and “indirect additive.” Printing inks and food packaging coatings may be indirect additives, and they may have direct, indirect or incidental contact with the food. This means that they are not intended to become a part of food, but they may in fact do so through some type of food contact. Considering the following regulatory definitions and exclusions helps to clarify the difference:

Migration Data. According to 21 CFR 170.3(e), food additives do not include substances that do not migrate to food. It states: “If there is no migration of a packaging component from the package to the food, it does not become a component of the food and thus is not a food additive.” Thus, if there is acceptable data to show that a substance does not migrate to the food, FDA premarket clearance is not required. These data may be obtained in a variety of ways, from simple calculations to conducting migration studies using food-simulating solvents.

Functional Barriers. Often, a food packaging supplier will mention that a functional barrier excludes substances from becoming a component of food. This concept dictates that if a substance is not part of the food contact surface and is separated from the food by a barrier that prevents migration of the substance into food, then the substance is not a food additive and is excluded from the FFDCA definition of food additives. Establishing the existence of a functional barrier should include either migration testing or structural analysis using anticipated exposure conditions.

Housewares Exemption. Food packaging suppliers may rely on the “housewares exemption” to exempt their coating from FDA’s premarket clearance authority. There is no statutory or regulatory definition of a “houseware,” and FDA has not codified a housewares exemption. The definition of a “houseware” has evolved to include cooking utensils, paper cups and plates, plastic eating utensils and tableware. Since it is the responsibility of the producers of housewares to ensure their products are suitable for use with food, a safety determination that includes migration data is strongly recommended by FDA.

Indirect Food Additives Regulations. If a coating is reasonably expected to become a component of food, FDA regulates it, and prior to market introduction, one of these five clearances must be established:

• Substances permitted by an effective FCN. Unlike food additive petitions that resulted in CFR listing, only the submitter and its customers may rely on an effective FCN. Effective FCNs are published on FDA’s website. On rare occasion, FDA may require a food additive petition.

• Substances permitted by regulation in 21 CFR 175, 176, 177, 178.

• GRAS substances as determined by FDA. Many of these substances are listed in 21 CFR Parts 182, 184 and 186, or are published on FDA’s website. Sometimes these substances are only limited to the specific application for which the determination was made.

• GRAS substances as determined by qualified experts without FDA approval or notification. These are commonly referred to as GRAS self-determinations. FDA acknowledges in 21 CFR Part 182.1 that the list of GRAS substances is not exhaustive. This implies that manufacturers are free to make their own determination of safety. This approach, when done thoroughly, includes the depth of chemistry and toxicology data required as part of the FCN process.

• Prior sanction substances or substances that were approved for use before the FFDCA in 1958. The prior-sanctioned status of a substance is a straightforward determination that depends solely on the existence of an appropriate pre-1958 letter from either FDA or the U.S. Department of Agriculture (USDA).

21 CFR 170.30(6)(g) states: “A food ingredient that is not GRAS or subject to prior sanction requires a food additive regulation promulgated under Section 409 of the Act before it may be directly or indirectly added to the food.” Thus, a substance essentially becomes a food additive only if it fits into one of these categories.

Good Manufacturing Practices (GMPs).

As mentioned in 21 CFR 174.5, there are GMPs that apply to indirect food additives, which also should be considered. In particular, GMP guidelines require that the quantity of indirect additive that is used is not more than is reasonably required to accomplish the intended physical or technical effect in the food contact article. The substance must be of a suitable purity for the intended use and must not impart an adverse taste or odor to a food product. Several of the CFR sections contain references to quality assurance tests, such as 175.300, 175.320 and 176.170. It should be noted that these tests are less rigorous than the testing required for a FCN.

Regulations Applicable to Inks and Coatings
21 CFR has two parts that directly apply to many inks and coatings, Parts 175 and 176. The former, Part 175, Indirect Food Additives: Adhesives and Components of Coatings, includes four regulations with broad utility. These are

• 175.105: Adhesives for use as components of articles intended for use in packaging, transporting or holding food.

• 175.125: Pressure-sensitive adhesives for use as the food contact surface of labels and/or tapes applied to food.

• 175.300: Resinous and polymeric coatings intended as the food contact surface of articles intended for use in producing, manufacturing, packing, processing, preparing, treating, packaging, transporting or holding food. These are coatings that must be continuous coatings and, in many cases, may be crosslinked.

• 175.320: Resinous and polymeric coatings for polyolefin films. This lists substances that may be used as continuous coatings over polyolefin films listed elsewhere in the CFR.

Part 176, Indirect Food Additives: Paper and Paperboard Components, includes many regulations, two of which are of general interest to ink and coating applications for food packaging. Substances identified in these regulations may be safely used as components of the uncoated or coated food contact surface of paper and paperboard intended for use in producing, manufacturing, packing, processing, preparing, treating, packaging, transporting or holding of food. Part 176.170 applies to surfaces exposed to aqueous and fatty foods. Part 176.180 applies to surfaces exposed to dry foods.

The regulation in Part 176.170: Components of Paper and Paperboard in Contact with Aqueous and Fatty Foods, is divided into two sections. Section (a)(5) contains a list of substances that may be used without meeting quality assurance tests, as long as they follow the limitations mentioned in the section. While this is a long list, the substances listed have limited use in ink and coating applications. Most of the substances are for use in papermaking or to achieve specific paper properties. Section (b)(2) contains a list of substances that may be used, but that also must meet the quality assurance tests mentioned in Paragraph (d) of this section. These tests require that the extractives do not exceed 0.5 mg/in2 of food contact surface. For various food types and temperatures, there are different solvents and extractive conditions to model the application. Tables detailing both food types and conditions of use are found in this regulation at www.cfsan.fda.gov/~rdb/opa-fcn3.html.

Also of interest is Part 176.180, which addresses components of paper and paperboard in contact with dry food. Dry foods are Type VIII and IX foods as mentioned in Table 1 of 176.170. Substances listed in this regulation are not required to meet quality assurance test limits.

Determining FDA Status
Coatings and inks manufacturers and food packaging purchasers can take several steps to gather information to determine whether substances are considered food contact or additives, or not. First, the substrate identity (paper, polyolefin, polyester, etc.) of the substance should be determined, and then the use conditions (microwave cooking, room temperature, etc.). Next, food types to which the coating may be exposed should be identified. For general purpose applications, such as paper plates, this will include all food types. The supplier of the food contact substance should provide information on FDA clearances for each coating ingredient. If they cannot supply this information, the coating manufacturer should be very cautious about using the ingredient.

In addition, the presence of a functional barrier between the coating and food will help determine its proper application and use. If an acceptable functional barrier exists, the coating is prevented from migrating to food. Therefore, it is not reasonably expected to become a component of food, and is not subject to regulation. In the absence of a functional barrier, the next step is to review the substrate, use conditions, and food types and determine if all components are permitted for use under these conditions. If they do not conform, or if the restrictions are not acceptable for the application, the coating must either be reformulated with substances that are acceptable, or migration studies must be conducted to determine safety.

Migration studies should be performed as described in FDA’s chemistry and toxicology guidance documents to assure that the testing is acceptable for supporting a safety determination. If there is no migration, the ink or coating does not become a part of the food, under the test conditions, and is not a food additive. At this point, the coating manufacturer has two options: File a FCN with the FDA, or if a coating substance(s) is extracted, take actions to determine the potential exposure. If the exposure is low, the manufacturer can either file a FCN or make a GRAS self-determination. If too much substance is extracted, the ink or coating ingredient is not appropriate for the intended application and should not be used.

For an in depth look at Food Packaging Inks and Coatings as they relate to compliance please visit the FDA’s website.

Article written by By Lisa Barrientez and Paul Strege and published by Food Safety Magazine

Custom Coatings: How to adhere to 4 hard-to-bond food packaging surfaces

The food packaging industry is home to a variety of packaging, from high glosses that boost shelf appeal to wax boxes that increase functionality. Whilcustom coatings e these unique packaging materials offer a competitive edge in the food industry, they are much more difficult to adhere to and often require specialized adhesives.

Without the right adhesive, you may face pop-opens and other sealing failures, increasing the amount of money and time spent on rework and scrap. By working with their adhesive suppliers, adhesive users can ensure they are using the right product for their food packaging application.

Here are four different types of hard-to-bond paper stocks you might be using for your food packaging, and tips on how you can get better bonds.

1. Wax coatings or wax impregnated

On a warm summer day, many of us enjoy grilling out on the patio and eating a delicious meal with friends and family. It’s not often we consider the way that these foods are shipped and safely arrive at the grocery store for us to purchase.

Poultry, seafood, produce and other perishable food items can get messy during shipping, which is why these products require a special packaging solution to ensure they safely reach their destination. Boxes coated or impregnated with wax are commonly used for these types of foods.                     

Wax is curtain coated or impregnated into various paper stocks to act as a moisture barrier between the paper fibers and food product. In curtain coated boxes, the wax is concentrated only on the surface of the paper stock, making it difficult for an adhesive to penetrate to the fibers and form a bond.

Wax-impregnated boxes contain wax throughout their fibers. Although these boxes have a higher wax content, the wax is not as concentrated on the top layer, making it slightly easier to bond.

For these types of packaging, we would recommend an adhesive with a long open time, enabling it to penetrate through the wax and form a full fiber-tearing bond.

2. Recycled content

Did you know that corrugated is the most-recycled packaging material on earth? In fact, the average corrugated box consists of 46% recycled fiber.

Just about every product under the sun is shipped using corrugated packaging. It’s rare to find corrugated that isn’t recycled, especially with the prominence of sustainable packaging. Although good for the environment, recycled fibers are more difficult to bond than virgin.

Recycled corrugated is manufactured by breaking down previously used paper and corrugated into pulp, removing contaminants and then reforming into new boxes. The breakdown process means recycled fibers are shorter and more compact than the original fibers, making it harder for adhesives to penetrate and form a good mechanical bond.

Virgin corrugated is less dense due to the longer interwoven fibers allowing adhesive to better wet out and form a bond. Like a tree growing roots in clay versus aerated soil, adhesives can form their “roots” easier on virgin fibers, than on dense recycled fibers.

More commonly, we are seeing adhesive users working closely with their suppliers so that they can pinpoint a specific adhesive—from the many available—to seal their recycled corrugated packaging.

3. High-gloss coatings

Walking through the grocery store aisle, there are many types of packaging—some more appealing than others. You may even be compelled to purchase a product over another due to its packaging. What is it that makes it more appealing?

High gloss, colorful packaging tends to stand out on store shelves and is eye-catching to consumers. Although this type of packaging attracts shoppers and differentiates itself from competitors, its high gloss surface (whether it is polyethylene, polypropylene, metallized or something else) is difficult to bond, often requiring a specialized adhesive.

The smoothness and often low surface energy of a high-gloss carton makes it difficult for adhesives to “wet out” and penetrate the surface. Unlike traditional corrugated adhesion, the hot melt doesn’t bond like a tree forming roots in the ground; rather, the chemical bond behaves more like a magnet. The two materials are attracted to each other because of their chemical make-up, not the mechanical adhesion of a root.

When adhering a high-gloss paper stock, we recommend working closely with your adhesive supplier since this particular application requires a specific hot melt with the ability to form a chemical bond to the surface of these high gloss paper stocks.

4. Clay coatings

Consider which logo would stand out more—the one printed on plain, recycled brown paper stock or the logo on white, clay-coated paper stock?  Often the latter, as clay coatings improve brightness and tend to really give any design printed on them that extra “pop,” so that the overall packaging appeals to customers.

Printing on a clay-coated paper stock also reduces the amount of ink used since it does not readily absorb it, unlike an uncoated paper stock. This same concept of resisting absorption is what makes adhesion to this surface difficult. Just as clay-coated paper stock doesn’t absorb ink, it doesn’t allow adhesive to easily penetrate its surface, making it difficult to form a bond.

Adhering clay-coated paper stocks requires a specialized hot melt that has the ability to “wet out” on the surface of the coating. This will allow the adhesive to “bite” through the surface and achieve a good, fiber-tearing bond.

As with all of the hard-to-bond coatings we’ve discussed, we cannot stress enough the importance of working with your adhesive supplier to help you find the right solution that will work for your specific application, whether it is bonding wax boxes, recycled corrugated, high-gloss or clay-coated paper stock. Having a trusting relationship with your adhesive supplier will set the foundation in optimizing your overall packaging process.

Lauren Oliva is the marketing communications specialist for RS Industrial, an adhesive manufacturer and distributor that has been helping customers improve their adhesive processes for more than 22 years. She is passionate about educating audiences as she works with packaging industry experts to provide informative content that is technically focused, yet clear and engaging.

Published by Packaging Digest

Written by Lauren Oliva in Adhesives on June 16, 2015

Liquid Packaging Market to Grow by 5.4% CAGR to 2021

Flexible Packaging for Liquid Product is on the Rise

Liquid packaging

The market size for liquid packaging is projected to reach $370.75 billion by 2021, registering a CAGR of 5.4% between 2016 and 2021, driven by high demand from the food and beverages industry while flexible liquid packaging is the fastest-growing liquid packaging type, globally.
According to a new report available through ReportsnReports.com, India, titled Liquid Packaging Market by Packaging Type (Flexible, Rigid), Resin

Increasing demand from the food and beverages industry is the major driver for the liquid packaging market. The global liquid packaging industry is expected to rise with increasing demand from the food and beverage industry in economies such as India, China, Africa, Middle East, Germany, Brazil, and others. Increasing carbon footprint due to use of various resins in the manufacturing of liquid packaging is the major restraint affecting the growth of the market.

Flexible liquid packaging is the fastest-growing liquid packaging type. This packaging type provides various advantages such as longer shelf life, less cost, consumer friendly, capable of retaining freshness of products, less energy consumption, green packaging, and others. Films are the largest flexible liquid packaging type used in the packaging of liquid products. Liquid packaging is widely used as it prevents the loss of moisture or protects the goods from moisture, improves tear, scuff, and puncture resistance, and provides a heat sealable surface.

Asia-Pacific is the largest market for liquid packaging globally, with China being the most dominant market. This region is also anticipated to witness highest growth rate, which is attributed to the rapid economic expansion in the region.Rapid development in the liquid packaging industry is also vigorously driven by the demand from food and beverages, medical and pharmaceutical, and other end-use industries in the region.

The report also includes company profiles and competitive strategies adopted by the major market players such as The Dow Chemical Co. (U.S.), International Paper (U.S.), Tetra Pak International S.A. (Switzerland), Smurfit Kappa (Ireland), Mondi Plc. (Austria), Sidel (Switzerland), BillerudKorsnäs (Sweden), Elopak (Norway), Evergreen Packaging (U.S.), and Weyerhaeuser (U.S.).

Learn more about custom aqueous coatings for flexible packaging here.

Article published by TAPPI, November 2016

What Sets UV, Aqueous and Laminates Apart?

Screen Shot 2016-01-24 at 1.50.00 PMGraphic finishers and commercial printers alike have constantly dealt with the challenges of matching the right coating or laminate with the printed sheet. Many factors are involved in this decision that can affect the outcome of the project. And while no set rules exist on choosing one over the other, there are specific advantages and disadvantages of each process that can help determine the best overall choice.

Ultra-Violet Coatings
UV is a very popular coating choice due mostly to the high gloss finish one can achieve, adding a brilliance to the finished sheet unlike any other coating method. UV coatings also provide good resistance to solvents and abrasion – much better than most water-based coatings. Because of its high sheen, UV coatings are popular on a wide variety of consumer products, including paperback books, trading cards, and cosmetic packaging.

However, UV coatings are not the best choice for all applications. Special precautions are necessary, especially when hot stamping foil, scoring, folding, or gluing is involved. Certain types of UV coatings can also cause cracking problems if the sheet or carton is to be scored and folded. UV coatings are a challenge when foil stamping is involved as well. If the coating has a high level of silicone, hot stamping foils will simply not adhere. Even special UV coatings without a heavy silicone addition are difficult in many situations. It is suggested to foil stamp first and then apply the UV coating to avoid potential problems. Even in this scenario, the foil stamper should check with its foil supplier to choose a foil that is overcoatable.

In addition, UV coatings have been known to yellow over long periods of time and are highly susceptible to fingerprinting. Environmental concerns also surround the use of UV coatings. Although very little waste is left to dispose of when applying UV, what is left is very toxic. Special arrangements are necessary to dispose of this waste.

Aqueous Coatings
Probably the number one advantage of aqueous coating is the cost savings you can achieve – especially in sheet-fed applications. Aqueous coatings are very user-friendly when additional finishing is necessary as well. They work efficiently over most printing process inks, wet over wet or in some cases, wet over dry. They also accept many glues and are very receptive to hot stamping foil.

Aqueous coating is promoted as environmentally friendly. There is a small percentage of solid waste (about 10%) left from an aqueous run and should still be handled with some precautions. It is certainly the environmental choice when compared to UV or film lamination.

Thermal Film Lamination
When protecting the printed sheet or carton from abrasion, chemicals, or even when fingerprinting is of utmost importance, film lamination is the best choice without exception.  Film lamination is available in several matte and gloss finishes and can even be applied with a special embossed roller that leaves a textured pattern over the laminated sheet.

As the number one advantage of aqueous coatings is the cost savings, a major deterrent to the use of film lamination is the price. High volume production of many packaging applications prohibits the use of thermal lamination because of the expense of the film itself and the slower off-line application used to apply the film compared to UV or water-based coatings. In addition, certain types of film laminates have a very low dyne count, meaning the surface tension of the sheet restricts the adhesion of other finishing processes, including hot stamping foils and glues. In the past, the film was corona treated, providing an acceptable surface. The challenge was that the corona treatment would wear off over a period of time. Special films have now been developed with a permanent chemical additive that will readily accept hot stamping foils and glues. If you have questions on the overstampability of the film, it may be wise to consider foil stamping before laminating the sheet.

As you can see, a great deal of analysis must go into the decision when choosing between UV coating, aqueous coating, and film lamination. From a graphic finisher’s point of view, you might think steering your customer towards UV or lamination (because you offer the service and know aqueous will be applied in-line) is the best choice. This certainly is not the right approach for long-term growth with the customer. Helping printers or other customers you work with analyze the advantages and disadvantages of the different coatings and laminates available and helping them match the right choice with the right application will solidify your position with the customer. Suggesting aqueous over UV when the application warrants it, will translate to a happier customer and a longer lasting relationship for the future.

Editorial by FSEA.com