Archive for the ‘Front Page Case Study’ Category

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.

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.