Easytech Packaging, an Italian manufacturer of metal cans and lids, has switched its production to PVC-free coil coating with its entry into the growing pet food market. This new formulation, particularly in combination with the processing of the cans on new high-speed lines, brought a series of technical challenges that were overcome in collaboration with Henkel Adhesive Technologies.
As a manufacturer of metal cans and lids, Easytech Packaging has long been familiar with the requirements of the food industry. By entering the growing pet food market, the southern Italian company took the next step – and was faced with new process requirements. At the same time, the company switched its production to PVC-free coil coating. This new formulation, especially in combination with processing the cans on new high-speed equipment, presented a number of technical challenges. In collaboration with Henkel Adhesive Technologies, the supplier of the food-grade, water-based sealant Darex WBC 733 PHV for can end production, Easytech managed to stabilise its processes and ensure product quality.
The entry into the pet food packaging segment began with a major order from a leading brand manufacturer to Easytech.
„This contract has opened up a completely new market for us. The requirements in the areas of sealing, food safety, and process stability are similar, but in some aspects even more complex than those of the human food industry. At the same time, production speeds and material combinations are more challenging. To meet all these demands, we had to fundamentally reconfigure our processes.“
Dr Fabio Bove, General Manager at Easytech
Easytech invested in four modern high-speed systems, so-called Rotary Liners, which allow up to 1,200 lids to be produced per minute. The customer's specifications also required the use of a PVC-free industrial coating.
Technical hurdles in the transition
The switch to PVC-free coil coating in combination with the sealant Darex WBC 733 PHV from Henkel presented considerable technical challenges. In particular, the precise placement of the sealant on aluminium lids proved complex. The rotary liners, which apply the adhesive by rotation, required high precision.
„The simultaneous introduction of new machines, a new substrate, and a new material for the cans and lids was a real challenge. This is where Henkel's experience made the crucial difference.“
Giuseppe Scarola, Operations Manager at Easytech
Optimisation through collaboration
In close collaboration, Henkel and Easytech optimised the machines and application parameters. A key factor was the revision of the sealant's stirring process. Henkel identified the insufficient homogeneity of the sealant as the main cause for the initial difficulties. The installation of a new agitator achieved a significant reduction in the de-wetting effect.
Successful stabilisation of production
Following intensive testing phases and optimisation, the production of can ends has been running stably for over 12 months. Scrap rates have decreased, and the end customer's requirements are being met. Fabio Lanaro from Henkel highlights the collaborative partnership, which was crucial for the project's success. Henkel supported Easytech both remotely and on-site to ensure stable production.
The successful transition to PVC-free coil coating demonstrates that complex technical challenges can also be overcome with the right expertise and a collaborative approach. Easytech and Henkel are continuing their collaboration to maintain production stability in the dynamic animal feed segment.
Source: Handle
