Drip EMS

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 

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

Soft Feel Coatings Enhance Haptic Feel

soft feel coatingsSoft Feel coatings, also known as Soft Touch® are manufactured to create a smooth, leathery surface and enhance tactile appeal of printed substrates like paper, film and foil including nylon, PET and OPP. Soft Feel coatings dry quickly and are non-yellowing, offering a lasting, finished look in end use applications. Often used to deliver high clarity and matte muted graphics, these aqueous coatings offer a luxurious, sophisticated look while providing a scuff and mar resistant barrier to printed substrates.

Soft Feel Coatings and Graphic Arts 

Known for excellent print receptivity, Soft Feel coatings are a popular option for darker color palettes, making them appear muted and offering a rich, more luxurious finished look. Soft Feel coatings are generally applied to a semi or high gloss surface, to avoid flattening of the printed graphics post-production. Receptive to a wide variety of inks, these coatings are manufactured to work well with solvent borne, water based, UV and offset inks.

Soft Feel coatings are applied in-line during the printing process and protect the substrate from abrasion. Converters use Soft Feel coatings to avoid purchasing secondary matte films to achieve the same matte look and feel. Film laminates also use Soft Feel coatings to create a scuff and mar resistant clear matte appearance while offering a surface that does not change gloss when scuffed or marred like traditional aqueous matte coatings.

Soft Feel coatings are commonly used for end use applications like:

  • Printed marketing materials
  • Food & beverage product packaging
  • Over laminate films
  • Book cover paper stock

For more information about aqueous Soft Feel coatings, please contact Roymal, Inc. at roymal@roymalinc.com or by calling (603) 863-2410.


Aqueous Ultraviolet (UV) Cure Coatings

Pushing the Limit of Aqueous Coatings

flexible packaging

Packaging engineers, print designers and graphics art professionals are constantly creating new applications that push the limits of aqueous coating technology.

These higher performance applications require aqueous coatings that will perform under the most severe conditions.  Roymal offers a wide variety

of aqueous UV curable coatings that are formulated to perform as primers and topcoats, our coatings offer excellent adhesion to films, are heat and chemical resistant and can be applied to paper, paperboard, foil and film products.

Application of Aqueous Ultraviolet (UV) Coatings

Commercial printers frequently send their jobs through using an inline UV curing equipment or an offline, “stand alone” UV curing unit. Aqueous (waterbased) UV cure coatings require the use of a thermal oven to remove the volatiles before the UV curing step.  The UV curing step can also be accomplished in an offline UV cure unit as the aqueous UV coatings have non-blocking properties and can be rolled in reel form prior to UV cure.  Aqueous UV primers and topcoats can be applied via rotogravure and meyer rod.

Roymal Inc. has formulated a select number of aqueous UV coatings that allow printers to take advantage of this unique technology for their variety of end applications, including ink receptive primers (can covalently cure with UV inks) and topcoats.


Roymal Inc. Offers Aqueous UV Curable Coatings like:  

  • UV Curable Print Receptive Primer
  • UV Curable Topcoat
  • UV Curable Soft Feel Topcoat
  • UV Cure Inline or Offline


Aqueous UV Curable Coatings offer:

  • Gloss or Matte Availability
  • Excellent Water Resistance
  • Excellent Rub Resistance
  • Excellent Chemical Resistance
  • Excellent Heat Resistance
  • Excellent Filmic Adhesion Properties
  • Good Print Receptivity

For more information about water based coatings and aqueous UV curable products, contact Roymal Inc. at roymal@roymalinc.com or by calling (603) 863-2410.

Custom Aqueous Coatings for Flexible Packaging Applications

A Leader in Custom Aqueous Coatings


Roymal, a leader in custom aqueous coatings, has made its mark among the flexible packaging and consumer goods  industry by manufacturing unique, innovative, problem solving solutions for today’s converting industry. Roymal’s custom aqueous coatings offer superior functionality to complex food packaging applications that are manufactured with a range of substrates which include paper, film and foil.

Roymal’s waterbased custom coating technologies include:

  • Overprint Varnish (gloss or matte)
  • Ink Receptive Primers
  • Heat Seal (lidding and blister)
  • Moisture Barrier
  • Heat Resistant (stand up pouches)
  • Insulation Coating
  • Security Coating

Well known for their superior functionality and unique characteristics, these custom coatings offer qualities that enhance the performance and print quality of flexible packaging and consumer goods products.

Waterbased Heat Seal Coatings

Roymal’s heat seal coatings are generally comprised of acrylic chemistries but also use polyurethane chemistries when applicable. Our heat seal coatings can be sealed coating to coating or coating to substrate, depending on the end-use application. Typical heat sealing conditions have temperature ranges from 225-350°F with 40-80 psi pressure and 0.1-1.0 seconds dwell time.

Heat Seal Coating Substrates & Printing Processes

Peel strengths can be customized pending your coat weight and substrate specifications. Typical examples of laminations include paper to paper, paper to film, paper to foil, film to film and film to foil. These coatings are applied to paper, paperboard and film using the standard printing processes, i.e., rotogravure, flexographic and offset. Heat seal coatings can be used not only for an overall surface coating, but also for pattern coating, in which the heat seal is printed only on those parts of the packaging that need to be sealed.

Heat Seal Coating Product Features:

  • FDA Approval
  • Broad Substrate Adhesion
  • Water Resistance
  • Chemical Resistance
  • Custom Peel Strength
  • Tailored COF
  • Gloss or Matte
  • Custom Pigmented Formulations

For more information about custom waterbased coatings for flexible packaging, please contact Roymal at roymal@roymalinc.com or by calling (603) 863-2410. Our custom coating specialist will work with you to develop tailored solutions that meet your needs.

Waterbased Polyurethane Coatings for Flexible Packaging and Graphic Arts

flexible packaging coatingThe uses of waterbased polyurethane coatings in the flexible packaging and graphic arts markets offers a broad spectrum of solutions and benefits. Polyurethane topcoats, overprints and primers can enhance a product’s appearance and lengthen its lifespan, making it a vital property in the manufacturing of films & product packaging. Custom formulated polyurethane coatings are common among industries like:

·      Flexible Packaging

·      Industrial Graphics

·      Film Coatings

·      Paper Packaging

Polyurethane Coatings Include Topcoats, Overprints and Varnishes

Roymal manufactures custom topcoat chemistries that deliver a variety of benefits to the film converting, printing and graphic arts industry. Polyurethane can enhance the aesthetics of a finished product, by adding a matte, gloss or soft feel finish. Polyurethane properties include flexibility with abrasion, chemical resistance, water resistance and print receptivity to a wide variety of inks including UV, digital and offset. Those benefits include:

Polyurethane overprints are used to protect and lengthen the lifecycle of printed flexible packaging, making them resistant to harsh conditions. They are highly durable to prevent damage from UV, abrasion and exposure to various chemicals. They are conformable for ease of use and when printed on, as well as protect the image and maintain the integrity of the product over time. They are ideal for commercial applications that risk exposure to environmental elements including weather and temperature extremes.

For more information about custom polyurethane coatings please contact Roymal Inc., at (603) 863-2410 or email roymal@roymalinc.com.



Waterbased (Aqueous) Coatings & Common Printing Technology

waterbased aqueous coatings for product packaging Aqueous coatings have been in use by commercial packaging professionals for nearly three decades. As the demand for aqueous coatings grows, print technologies become more advanced. Three common print technologies are used to print aqueous coatings. They are flexographic, gravure and offset printing.

Aqueous coating vs. traditional overprint varnish:

• Good gloss
• Increased rub resistance
• Smoother feel
• Elimination or reduction of spray powder applications
• Faster handling of the printed products
• Decreased application time

The type of aqueous coating required depends heavily on the application. Below are three of the most common printing techniques for aqueous coatings.


Flexography (often abbreviated to flexo) is a printing process which utilizes a flexible relief plate. It is essentially a modern version of letterpress which can be used for printing on almost any type of substrate, including plastic, metallic films, cellophane and paper. It is widely used for printing on the non-porous substrates required for various types of food packaging (it is also well suited for printing large areas of solid color).


Rotogravure (roto or gravure for short) is a type of intaglio printing process, which involves engraving the image onto an image carrier. In gravure printing, the image is engraved onto a cylinder because, like offset and flexography, it uses a rotary printing press. It is often used for commercial printing of filmic substrates and other product packaging.


Offset printing is a commonly used technique in which the inked image is transferred (or “offset”) from a plate to a rubber blanket, then to the printing surface. When used in combination with the lithographic process, which is based on the repulsion of oil and water, the offset technique employs a flat (planographic) image carrier on which the image to be printed obtains ink from ink rollers, while the non-printing area attracts a water-based film (called “fountain solution”), keeping the non-printing areas ink-free. The modern “web” process feeds a large reel of paper through a large press machine in several parts, typically for several meters, which then prints continuously as the paper is fed through.

If you have questions about our custom formulated coatings, overprint varnishes, primers or print technology, please contact Roymal, Inc. for assistance at (603) 863-2410 or email roymal@roymalinc.com.