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High-Tech Coatings Enhance the Efficiency and Performance Of Philip Morris created for its Benson & Hedges 100’s DeLuxe Ultra Lights Spotlight Report in a flip-top box was certainly no exception. ® Packaging Machinery Packaging such boxes normally requires special attention to avoid scratches on the film and scuffs on the blank, but the unique construction of the DeLuxe Lights pack blank compounded the problem. In addition High-tech coatings enhance the efficiency to the highly reflective surface and the embossed crest, the clear and performance of packaging equipment polypropylene film had to be free of scratch marks. Adding a protective coating to the FDA, USDA, NSF & AgriCanada-compliant coatings provide hardness, corrosion packaging machine parts seemed the resistance, dry lubricity and long life for all types of metal parts on machinery. Side folding plates (left) and bottom fold plates (right) on the over-wrap machines used to obvious answer to the problems, but wrap Marcal Paper's pocket tissue packs have been protected with Magnaplate HCR® to resist wear and reduce down time. conventional coatings such as nickel, ackaging engineers face a wide chrome and similar attempts from variety of challenges when it Folding plates unit, according to a company source. past experience did not solve them. Pcomes to maintenance and Coating avoids abrasion and It would also eliminate costly down- Either the scratches in the polypropy- operation of a broad spectrum of corrects skewed overwraps time problems. machinery counted on to perform “We knew exactly what we had to such tasks as wrapping, sealing, cut- Marcal Paper Mills, Inc., Elmwood have,” said Marcal’s director of con- ting, forming, pouching, blister pack- Park, NJ, was facing the challenge of verting. “We needed to find a double- ing, folding, strapping, trimming, fill- skewed overwraps, unsightly bubbles, characteristic coating that would be ing, and conveying. Some of those and out-of-square labels. Packaging so ultra-hard that it would, first, make problems include: engineers saw these problems as a the susceptible aluminum packaging I Poor lubricity and premature wear forewarning of impending machine machine parts become as wear-resis- of folding plates on overwrap jams and resolved to do something tant as stainless steel. Second, we machines can cause skewed over- about the challenge before the pack- wanted those coated parts to exhibit a wraps, bubbles and machine jams. aging problems spilled over into cus- level of lubricity that would diminish tomer dissatisfaction for the compa- the generation of friction and elimi- Abrasive wear of nozzle collars, ny’s high-quality napkin and facial cross sealers, quench sealers, filling nate drag in the same way a propri- tissue product lines. etary non-stick tape does. nozzles and side sealers can stop Engineers knew that they were fac- packaging operations cold or shorten “It didn’t take us long to make up lene overwrap caused a clouded ing packaging problems frequently our minds once we learned about and image or the sensitive packaging the useful life of the machinery. encountered wherever polyethylene I evaluated Magnaplate’s HCR® syn- coating was scratched. When those Accumulations of adhesives, overwraps are applied in high-speed ergistic coating.” glues, packing films, inks and prod- mishaps didn’t happen, the raised, packaging operations. They also Magnaplate HCR is a high-tech, embossed crest was badly scuffed or uct residues can “gum up” packaging knew that the prime source of the multi-step coating that gives alu- equipment surfaces, necessitating fre- smudged even before the overwrap problem was abrasive attack on metal minum an ultra-hard, corrosion resis- was applied. quent shutdown and maintenance of surfaces by microscopic-size particles Magnaplate HCR® "synergistic" surface enhancement on Marcal Paper's overwrap equip- tant, non-stick surface. Philip Morris engineers remem- equipment. of residual paper dust carried along “The extended machine-part life ment gives folding plate parts superior resistance to corrosion and wear. (Story on page 2) bered that a Magnaplate “synergistic” Friction on the surface of metal by the polyethylene sheet. The result we achieved as a result of the coat- coating had solved a similar packag- parts used on hoppers, chutes and over time was uneven machine wear How do the coatings work? and chemical attack. They each fea- ing of our initial test units,” reported ing machinery problem for them in other conveying equipment can cause and film jamming. Marcal’s director of converting, “has the past. It occurred to them that if product backups and bring pack- ture an extremely low coefficient of The machine parts most suscepti- High-tech Magnaplate-applied coatings friction to reduce galling of mating led us to coat the wear surfaces of all aging operations to a halt. are impregnated into the substrate of ble to uneven wear were the alu- our packaging machines with parts and to prevent any material minum bottom plates on the wrap- And if those challenges aren’t packaging machinery component metal from adhering to the equipment dur- Magnaplate HCR.” enough, special needs — such as cig- parts through a series of proprietary pers, the underfold plates and the side ing the packaging operation. folding plates — depending upon the arette packages which feature foil steps that include an infusion of selected Many of the coatings meet USDA, New cigarette pack panels and embossed hot stamping — engineering polymers. type of packaging equipment FDA, NSF, and AgriCanada codes, involved. Easily scratched poly film place special demands on the packag- Unlike “paint-ons,” these coatings making them excellent selections for complicates packaging ing engineer and the equipment for become an integral part of the base The packaging engineers knew enhancing the performance and wear what they had to do. They needed to Throughout the packaging industry it which he or she is responsible. metal and won’t chip, flake, peel or rub life of all kinds of metal parts on food It is the recognition of wear, abra- off. They are called “synergistic” find a protective, anti-abrasion coat- is generally true that the more attrac- or drug packaging machinery. Their ing that could be applied to exposed tive and distinctive the package, the sion, corrosion and release problems because the resulting surface is superior non-stick properties make sanitary such as these that has caused engi- in performance to the base metal or any metal surfaces to not only resist abra- more difficult it is to produce on clean-up a relatively simple matter of sive attack, but also lubricate the high-speed, high-volume packaging neers across the country and around of the individual coating components. fresh water rinsing. the world to turn to General A wide diversity of coatings is folding plates. equipment. An entirely new package Mirror-smooth Magnaplate HMF® coating Here are just a few of the pack- Such a coating would extend the developed for a new brand is bound on Philip Morris' cigarette packaging Magnaplate Corporation for solutions available for application on specific aging equipment part performance machine parts prevents scuffing, scratch- — in the form of their specialized, types of metal substrates. Each meets replacement free service life of their to compound all the normal problems ing or clouding of crystal clear polypropy- and maintenance challenges Magna- packaging equipment’s parts even many times over. lene overwrap, reflective foil panels, and high-tech, “synergistic” surface special performance requirements for plate coatings have solved. enhancement coatings. preventing wear, abrasion, corrosion beyond the normal span of a new The attractive cigarette pack that embossed 3-D crest . components to the potential for exce- the machines to operate at signifi- sive abrasive wear. cantly higher speeds without experi- Polypropylene strapping is auto- encing excessive wear of the parts. Aluminum coating matically fed around the entire alu- bar on Cozzoli minum yoke of the machinery and Separator fingers Machine's continu- tensioned to a pre-set pressure before ous filler is protect- Wear of aluminum reduces ed from wear and being sealed and cut off. efficiency of packaging corrosion by a The FMC strapping machines can TUFRAM® coating. apply up to 18 straps a minute — The abrasive action of paper products provided the steel and aluminum being collected between the alu- surfaces involved can maintain their minum fingers of a packaging smooth, unhampered action. machine’s separator caused a severe Experience has shown the company wear problem that impacted on the that the best way to assure that is by efficiency of operations. coating the aluminum yoke with The problems were eliminated by Magnaplate’s TUFRAM® and the coating the fingers with Magnaplate Filling machinery in a line of high speed stoppering steel components with NEDOX® to HCR, a surface enhancement coating Aluminum surfaces require machines. permanently lubricate and protect the exhibiting exceptionally high corro- the toughness of steel path traveled by the strapping during sion resistance as well as ultra-high Bagging chute hardness for superior wear resistance. Cozzoli Machine Company is a major the high-speed strapping operation. supplier of packaging equipment Abrasive wear causes back-up machines to the pharmaceutical and of diaper production Pouch packing cosmetic industries. It makes exten- A leading manufacturer of diapers Cigarette-making machine parts are coated to eliminate scratching of film and package. Faster production speeds with sive use of Magnaplate coatings for and feminine hygiene products in Magnaplate could keep dried packag- ness and clean appearance the pack- Magnaplate coatings improving part wear, reducing fric- Canada was encountering packaging ing glue from adhering tenaciously to ages demanded. A leading manufacturer of packaging tion and galling, and providing inert operation slowdowns because of a glue pots, then they should be able to The attention-getting new Benson equipment supplies a variety of drug surfaces where chemically active serious wear problem.
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