Archive for the ‘Board Laminating’ Category

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.

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.