Archive for June, 2013

Board Laminating Case Study

24th June 2013

We are proud to have developed a thorough audit process that has enabled us to get an in-depth understanding of our clients and their requirements. This is an important part of our process as it ensures we gather the information we need to give our clients the best possible level of service.

Earlier this year we worked with a large UK-based board manufacturer who had been using a low cost adhesive. The customer was running at a very high coat weight of adhesive which made it difficult to control bond curl. In order to minimise waste, it was important that this issue was resolved. The customer was also trying to achieve higher production speeds to further improve their profit margins.

Our team met with the customer and carried out a line audit. This is a key part of our process and is something we undertake with all new customers. We assessed the customer’s equipment and its capabilities, taking in to account their current working practices, views on their current adhesive and what they want to achieve.

This detailed level of understanding informs our recommendations and can sometimes mean we are able to put forward an existing product from our portfolio. We were able to show that our adhesive could offer them a higher quality finished product that would allow for cost savings as coat weights could be significantly reduced. AquaPAL® 9254 was better suited to the capability of their laminator, enabling them to run their machines at faster line speeds. As a result, we achieved the desired reduction in adhesive consumption of over 60% and were able to increase line speeds from 80m/min to 140m/min.

For more information about how we could support your manufacturing process, please get in touch with a member of our team using the details on our Contact Us page.

Tube Manufacturing Case Study

24th June 2013

Our technical abilities have made Pafra one of the leading adhesives manufacturers in the industry. We have earned our reputation as innovative problem solvers and have an array of pre-formulated adhesives available, and can also create bespoke products to meet our customers’ specific needs. Our production levels mean we can support multi-national brands, as well as smaller operations.

Last year our team met with a multi-national paper converter about an issue they were experiencing. The customer manufactures high quality convolute tubes for the drinks market. The company wanted to reduce the level of tube shrinkage occurring due to water evaporation as the adhesive dried. This meant that caps did not fit well and this was leading to a high rejection rate.

Our technical team carried out an extensive audit and ran trials with the premium product. We identified that their existing product had a low solids content. Excess water was being placed on the paper the tubes are made from, and a high volume of adhesive was being applied in order to achieve the desired level of stiffness.

By offering one of our products that had a higher solids content, the AquaPAL 9560, we were immediately able to reduce shrinking throughout the drying process as there was less water on the paper. We gave the customer a greater level of control and were able to reduce the volume of adhesive required due to the better flow characteristics of our adhesive. The rigidity of the tubes improved as our product dried a lot harder than their previous solution.

Having taken the time to fully assess exactly how the customer’s problem was arising, we recommended one of our existing products, AquaPAL 9560. After introducing our adhesive to their system, the customer was able to increase line speed by over 15%, could reduce their adhesive consumption by 50% and as there was less moisture in the tube, shrinkage was reduced. The cap now fitted better and their rejection rate reduced. The resulting tubes being stiffer, and therefore easier to cut, the customer provided a higher quality finished product.

To learn more about how our products could improve your performance speeds, please get in touch with a member of our team using the details on the Contact Us page.


Shelf Ready Packaging Case Study

24th June 2013

The technical staff at Pafra are known for their ability to create bespoke formulations for clients that are specifically tailored to exact requirements. As we have a vast library of pre-formulated adhesive solutions, we are often able to recommend a product we have already created. This was true of our work with a large UK-based corrugated converter.

The customer manufactures ‘four corner trays’ for the food industry and was looking to improve manufacturing efficiencies and expand their product portfolio. However, they were constrained as the trays were springing open after the compression section at line speeds in excess of 11,000 trays per hour.

After taking a detailed brief, we were able to recommend one of our existing premium carton converting products, AquaPAL® 9693. We chose this adhesive as it consistently performed well, but could also bond a wide range of paper based materials and is resistant to high and low temperature conditions.

AquaPAL® 9693 was a great success for the customer as it enabled them to double line speeds from 11,000 to over 22,000 trays an hour. As a result, they have also been able to broaden their product range to include trays for baking in the oven and products that can be frozen, then baked at home.

To learn more about how our products could improve your performance speeds, please get in touch with a member of our team using the details on the Contact Us page.

Envelope Manufacturing Case Study

24th June 2013

Our in-depth understanding of the adhesives industry has enabled our technical team to create a suite of adhesive products that meet a range of requirements. Understanding the capabilities of our products well, we can often recommend a pre-formulated adhesive once we have an understanding of the customer’s specific requirements. We recently worked with a large independent envelope manufacturer based in the UK and by introducing them to an existing adhesive in our product range, we not only saved them money, but also increased their line speeds.

The customer was experiencing wrinkling on the flap gum when working with low cost light weight Manila paper. Our ‘hands-on’ approach meant that the technical team conducted a full audit of the customer’s current production cycle. The line audit involved measuring the distance from the gluing station to the drying station until the end of the production line. We went on to ask a series of questions that allowed us to get to the bottom of how the product was currently performing, and what could be improved. After taking samples of paper, we were able to test a number of our pre-formulated products to determine which one was the most effective.

The AquaPAL 9929 LV was selected as the final product as it was designed to give exceptional lay flat performance. It enabled the customer to coat at a lower rate and prevent the paper from wrinkling. As a result of our process, knowledge and selected product, we were able to significantly reduce machine down time.  Line speed was increased by 15% as the adhesive does not cause crinkling when dried at a faster rate. The customer was also able to reduce the coat weight of the adhesive applied which reduced the cost of production.

To learn more about how our products could improve your performance speeds, please get in touch with a member of our team using the details on the Contact Us page.

Board Laminating Case Study

24th June 2013

We work hard to fully understand our customers’ requirements, and regularly create bespoke products should a pre-formulated Pafra adhesive not meet a customer’s specific needs. We recently completed an exciting bespoke piece of work for a large UK based board mill in the laminating sector.

The board mill had a customer looking specifically for a 100% compostable film coated board. The product needed to meet the EN13432 standard for industrial composting. This requirement was a good fit with our expertise as we have long been committed to using the most current and sustainable practices. Our compostable range of adhesives are an environmentally friendly alternative to traditional products and benefit from having high strength bond performance, a high adhesion performance and good machine performance.

Our team took a full and detailed brief to gain an in-depth understanding of the customer’s needs. We sourced a polymer that meets the EN13432 standard and created a new formula that would run on a conventional laminator. Having checked this polymer was capable of bonding the specific substrates, we needed to address the issue of polyurethane dispersion. This instability meant that the adhesive could be difficult to apply due to its fast setting nature. Polyurethanes work well for gravure coating and spraying with high volume, low pressure guns, but as other methods apply a lot of pressure on the dispersion this can cause it to collapse. This can prevent machinery from working and make it difficult to clean.

We had to carry out extensive laboratory work to make it possible to run this material cleanly on a conventional laminator. As the product was designed for Gravure coating, rather than laminating, we believe we are the first company to have created a compostable laminating adhesive for this application. As a result of our work, the customer was able to manufacture a home compostable laminate that meets the EN 13432 and are now manufacturing this product at high volumes.

For more information about how we could support your manufacturing process, please get in touch with a member of our team using the details on our Contact Us page.

Bag and Sack Manufacturing Case Study

24th June 2013

We take pride in providing innovative solutions to problems and giving customers the best possible level of service. We know that our expertise can save our customers time and money, and our work with one of the largest UK bag and sack manufacturers is a prime example of how our process can make a difference.

As a key supplier of the largest food francise packaging throughout Europe, the bag and sack manufacturing customer had a great volume of work to produce. The customer approached Pafra as they were having a high level of failures with the heat seal adhesive used on the packaging of an extremely high volume takeaway paper bag.

We quickly identified three raw materials that possessed the right characteristics required for this type of application. After testing them on paper samples supplied by the customer, we could select the right polymer for the customer’s substrates and processes. Our team then created an adhesive from this polymer that had the correct flow characteristics, setting speed and grab speed while ensuring the melt temperature remained in the correct range.

By creating a new product, AquaPAL 9483, we were able to give the customer an impressive zero failure rate. This change has meant the customer can increase their manufacturing rate by approximately 15%.

Following on from this success we won the business and our rapid response coupled with our level of service and expertise have lead to Pafra becoming the customer’s sole supplier. We have since collaborated on a number of projects, looking at new concepts and how we can formulate solutions for the implementation of these concepts from design, through to manufacturing.

To learn more about how our products could improve your performance speeds, please get in touch with a member of our team using the details on the Contact Us page.

Carton Converting Case Study

8th June 2013

Our expertise within the carton converting sector means we support a range of industries with their adhesive requirements. A large UK-based carton converting group approached us last year as their new Accuwin in-line window patcher required an adhesive to bond film to board and remain in place through the blast freeze process (-80C) as well as give a fibre tearing bond whilst stored in a freezer (-20C). We had already developed a product with these benefits. Pafra 9400 is the only adhesive formulation for window patching that gives a fibre tearing bond at -20C. Normally cartons are printed, cut, creased, window patched (10,000 cartons per hour) and then put though a carton folder gluer. By using an in-line window patcher on a carton folder gluer you can window patch at 30,000 cartons per hour. The customer required a specialist adhesive with the same performance as Pafra 9400 but for the new application method.

Although window patching is normally carried out using a stencil, the customer’s new system uses a block of 60 jetting nozzles. Jetting on this scale is problematic because if one jet blocks the whole machine will stop and need cleaning. The team at Pafra needed to ensure that the product would not block the jets and created a new formulation to meet these specific requirements. Our specialist understanding of rheology meant that we could ensure the formulation would jet with the right droplet shape with no teardrop or satellite formation. These anomalies can lead to dirty running and machine down time.

The end result of this process was a bespoke product that worked well in the application, having met the requirements set out at the beginning of the project. The customer was impressed by our technical capabilities as a number of multinational brands had not been able to satisfactorily resolve the issue.

To learn more about how our products could improve your performance speeds, please get in touch with a member of our team using the details on the Contact Us page.