Migrating to Water-Based Barriers: How to Transform Your Corrugator Without Downtime
Why Global Brands are Demanding Sustainable Corrugated
Stay Ahead of Global Regulations
With the PPWR and increasing plastic restrictions, sustainability is now a must-have. Brands like Unilever, Nestlé, and PepsiCo are actively seeking partners who help them meet their 2025-2030 goals.
Access High-Value Premium Markets
Differentiate your plant by entering high-margin segments: fresh food, frozen items, and sustainable e-commerce. Converters adopting these technologies report better margins and exclusive contracts.
Measureable Circular Economy
Unlike laminates, water-based barrier corrugated is a mono-material with recycling rates exceeding 95%. Help your clients hit their ESG targets with verifiable data.
Innovate Using Existing Equipment (Zero CAPEX)
Maximize your current assets. Our formulations are engineered to run on your existing flexo units and anilox rolls. The investment is in expertise, not expensive new machinery.
5 Stages for a Risk-Free Implementation
1. Define KPIs and Critical Applications
Identify the end-use (e.g., agricultural vs. delivery) and set clear success metrics: target Cobb (<15 g/m²), MVTR values, and wet ECT resistance.
2. Technology Selection and Lab Validation
Choose the exact formulation (water, grease, or both). Defining viscosity and dry coat weight in the lab first prevents costly errors on press.
3. Controlled Plant Pilot Trial
Execute a short run on a scheduled shift. Closely monitor film uniformity and drying performance under real production conditions.
4. Performance Validation in the Logistics Chain
Test the real-world behavior: stacking strength, cold room performance, and final print quality throughout the supply chain.
5. Industrial Standardization and Scaling
Turn pilot success into a standard operating procedure. Define operating ranges, train your team, and ensure shift-to-shift consistency.
Pre-Production Checklist: Success is in the Details
Verify these 4 critical points before start-up to ensure a perfect application:
- System Integrity: Clean anilox rolls and pulse-free pumping for a perfectly uniform layer.
- Drying Capacity: Confirm your dryers can handle the 20-40% extra energy required by water-based vs. solvent coatings.
- Chemical Compatibility: Validate anchorage with your current inks and adhesives to prevent picking issues.
- Environmental Variables: Monitor plant temperature and humidity to stay within the optimal operating window.
Quality Protocols: Measure What Truly Matters
Measure actual absorption: <35 g/m² for fresh produce and <20 g/m² for frozen applications.
A Kit 8+ value is the industry standard for protecting high-fat food packaging.
Crucial for sensitive products: <100 g/m²/day ensures structural integrity in humid environments.
Ensure clean die-cutting and gluing strength exceeding 2 N/25mm.
Low-Impact Pilot: Trialing Without Hurting Output
- Select a medium-complexity SKU with moderate volume for the first step.
- Schedule trials during low-demand shifts to allow for technical adjustments.
- Assign a dedicated QA lead to record every process variable in real-time.
- Define clear 'Go/No-Go' acceptance criteria before the machine starts.
- Conduct post-sale follow-ups to validate performance at the end customer level.
Common Pitfalls to Avoid During Migration
- Skipping the learning curve: Don't try to validate everything in a single run.
- Adjusting too many variables: Change the chemistry or the press settings, but never both at once.
- Working in silos: Involving operators and maintenance from day one is vital for buy-in.
- Scaling too fast: Never move to mass production without defining clear process limits.
Start Your Transition to Sustainable Corrugated
At Coaterex, we don't just deliver coatings; we partner with your technical team from selection to plant validation to ensure total success.
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