Shields Up!

Just how much do consumers realize how their food packaging protects them? Or what do they think really goes into that nice glossy cover for their favorite magazine? The answers are probably not much and they probably don’t give the cover a second thought. Nor do they realize why their paper cups are so impervious to the liquids inside them. No, consumers take all this for granted, not realizing that one major factor contributing to these effects is how the substrates are coated or laminated.

What’s shakin’?

In terms of equipment, there aren’t new demands being made of the coating and laminating market. Where the emphasis seems to be currently is on the development of various technologies. “Not much has changed in equipment demands relating to coating and laminating,” says Harry Challender, vice president of business development, -Davis-Standard. “The equipment demands are balanced between high-output lines for commodity type products and flexible lines that allow for rapid changeover for short-run specialty applications.”

Rick Ruenzel, director of business development, Midwest, West Coast, and Canada, Comexi, comments that the market will see the continued evolution of solventless adhesive technology and the refinement of the solventless process. “The use of UV/EB coatings will also increase within certain segments of the market, he says.

Current developments in this market are revolving, much like almost everything right now, around the environment. “We are working closely with suppliers and customers to develop equipment that can efficiently process new bioresins which have had a surge in interest in the last year and a half,” says Challender.

Joe Heinemann, president of Rayven, Inc. says that new developments in eco-friendly adhesives, substrates, and release liners will continue to come onto the market, but cautions that “at this point, they are not cost-competitive with traditional products. But over time this should change.”

Reducing the carbon footprint involved with coating and laminating will increase the amount of research into viable alternatives to more traditional, energy-intensive technologies according to Ruenzel. “This means that solventless technology will continue to expand at the expense of solvent-based and even water-based applications.” He adds that solventless is a zero percent VOC process and that solventless laminators are very energy-efficient because no drying system is required. “While it is premature to assess the future of EB or UV adhesive laminating,” he says, “it would be reasonable to assume that some applications within a narrow process range could emerge.” All that being said, Ruenzel claims that many applications that require solvent- or water-based adhesives and coatings will remain for many years to come. “It will be incumbent upon the machine manufacturers to develop more efficient drying systems that will reduce energy costs,” he asserts.

Market demands

Suppliers and package printers are coming up with some interesting applications for coating and laminating, and in turn, this changes their demands. According to Ruenzel, packaging converters are looking for more sophisticated structures using higher barrier materials such as multi-layer co-extruded films. “There is also greater demand to enhance the overall appearance of the package using coatings (such as EB, UV, etc.) or lamination,” he says.

“We have seen increased interest in high-performance hot melt adhesive coatings for label stocks as a way to reduce energy costs normally associated with drying adhesives,” says Challender.

Comexi recently demonstrated a triplex laminator at drupa with solventless adhesives. “Many of our custom machines are multifunctional, capable, for example, of solventless laminating or applying a UV or EB coating,” Ruenzel says. Another was developed, he comments, to laminate and then provide in-register microperforation. “Our capabilities with custom equipment have expanded enormously to address increased industry demand for this type of equipment.”

There’s the demand, now what are the converters doing?

For example, Heinemann says, “We recently produced a film/metal/film laminate label stock for the top seals on deodorant. The special pressure-sensitive adhesive was not affected by contact with the product and was designed to release cleanly from the deodorant top. The label stock was flexo-printed and diecut prior to being supplied to the company.”

To coat or not to coat

There are differing opinions as to whether most package printers are bringing coating and laminating operations into their shops. “Outsourcing is becoming a thing of the past,” says Ruenzel. “One of the significant trends in flexible packaging is the integration of various processes (printing, lamination, converting, extrusion) under one roof.” This allows greater flexibility, faster turnaround, and more control over the process, he says. “I believe that there is now a level of expectation on the part of their customers for a printer/converter to offer the complete range of manufacturing processes,” he adds.

On the other hand, Heinemann and Challender consider the size of the shop the contributing factor to whether coating and laminating are brought in-house.

“It would be difficult for the mid- to small-size printers to compete with the cost base that large integrated manufacturers enjoy, so we see limited inquiries in this area,” says Challender.

Heinemann echoes Challender. “Many larger package printers do their own coating and laminating to maintain a low-cost structure for high-volume products,” he says. “Outsourcing is used when the printer does not have the capability or capacity in house for the project.”

The bennies

Regardless of how the coating gets done, the benefits for the end user are many. Challender states that laminations or coatings occur when a single substrate cannot provide either the aesthetics or physical properties required for an end-use application.

“There are many applications for coating and laminating in the packaging arena,” says Heinemann. One of the most common, he says, is overlaminating a printed paper or film with a clear film. “This will increase the durability and water resistance of the substrate,” he says. “Pressure-sensitive adhesives are coated onto various substrates to make all types of label constructions. Release liners are coated with silicone and are used to protect the adhesive until it is needed. And various top coatings are applied to film substrates to improve their printability and to improve ink anchorage.”

Ruenzel asserts that coating and laminating are used for better appearance and/or properties for the package. “For example,” he says, “a coating or lamination is used to enhance appearance, increase scuff resistance, and allow better stacking. A salad bag might be laminated for appearance, but also for barrier properties for microwaveable applications. The list is endless.”

Ultimately, according to Ruenzel, the advantages for the printer and the end user are simple. “For package printers, it provides a more diversified and value-added product; for end users, extended shelf life, convenience, and safety,” he says. And, the consumers don’t even realize it! pP