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 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 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. come up with a coating that would be & Hedges package, with its richly and pharmaceutical companies with materials might contact the equip- Assembled diapers are sent down a smooth enough and exhibit a suffi- burnished colors, its highly reflective vertical and horizontal form-fill-seal ment components. conveyor and accumulated automati- ciently low coefficient of friction to finish, and its crystal clear overwrap machines for pouch packaging of vis- One of their large fillers is cally in the precise quantities to be handle the cigarette packaging prob- gives dramatic proof that Philip cous and aqueous liquid products, designed to handle irregularly shaped packaged. Bagging is initiated when lem, too. Morris’ packaging engineers have tablets, pre-moistened applicators, containers. The reciprocating head of an aluminum arm pushes the accumu- Magnaplate's engineers developed indeed met this major packaging and sterilizable hospital disposables the filler is timed to move with the lated diapers down a stainless steel a new coating called Magnaplate challenge. in permanent seal and peel-open A Magnaplate HCR¨ coating on the alu- conveyor belt so that the filling noz- chute and into the bag attached to the HMFª that imparts an ultra-hard, pouches. minum fingers of a separator eliminated a zle can enter, fill and leave the con- end of the chute. mirror-smooth micro finish surface Strapping machine severe wear problem caused by abrasive tainer without ever touching it. The problem occurred when the According to the manufacturer, the action of paper products which were being with the lowest coefficient of friction machines feature sealing head com- Engineers wanted to use aluminum arm scraped against the sides and bot- Aluminum and steel surfaces collected in the separator. for the filler heads, but they could not tom of the chute, leaving material on obtainable from any non-burnished face abrasive wear problems ponents and other key parts whose metal coating system. surfaces have been improved by syn- Forming rolls and throats until Magnaplate applied a TUFRAM the chute and creating friction that Unlike conventional coatings FMC Corporation’s strapping ergistic coatings. The coatings permit coating that allows the aluminum to slowed down the speed of the pack- which were considered and rejected, machines, known for their reliable, Abrasion prevention frees withstand the friction encountered aging operation. pharmaceutical product flow Magnaplate HMF coatings cannot high-volume strapping capabilities, Production speeds on form-fill-seal pouch between the moving parts of the After trying several options, the chip, flake, peel or be rubbed off. subject both steel and aluminum packaging machines were dramatically The Ivers Lee Division of Becton, assembly. packaging engineer reduced the size Important to the ease of cleaning, improved, without experiencing excessive Dickinson and Company specified Similar solutions using TUFRAM of the arm and had Magnaplate coat wear, after the sealing head and other parts for aluminum and NEDOX for stain- the sides and bottom of the chute speed of production, and the smooth- were enhanced by a Magnaplate coating. Magnaplate coatings from the start ness of the cigarette machine parts, when manufacturing its UtiliPack less steel were applied to drive and with PLASMADIZE¨. very few solid substances will perma- Machine, the BFH. The forming idler wheels and plugging heads, as The wear and friction problems nently adhere to a Magnaplate HMF rolls, which vacuum-shape the pass- well as to stainless steel and alu- were solved and the packaging effi- coated surface. And while some tacky ing web of film to create “pockets” minum parts on hoppers and chutes ciency restored. materials may exhibit some tempo- and heat-seal the web to a second rary adhesion, almost all substances sheet of film to form blister packages, release easily. are coated to prevent pick-up of To prevent pick up of It is this attribute that makes such freshly printed ink on the passing freshly printed ink “synergistic” coatings particularly film. and to prevent dust advantageous when employed in con- The “throat” of the machine is also accumulation, two coated. This is where aspirin and critical components junction with the sensitive packaging of this Ivers Lee blis- materials used in Benson & Hedges similar products are conveyed from ter pack machine, the DeLuxe Ultra Lights. The Philip the twin round hoppers at the top of forming rolls and the Morris engineers had early on discov- the web of film in which they are to throat, were protect- ered that not only would grooves and be sealed. Coating the throat prevents ed by Magnaplate scratches in the machine parts cause accumulation of dust from the motion coatings. problems to arise in the packages’ Aluminum yoke and a variety of steel com- of the tablets and also prevents mark- ponents on FMC's high-volume strapping appearance, but any pip or protrusion machine are protected against abrasive ing of the tablets — which would on the surface of the metal would be wear by Magnaplate "synergistic" dry- occur if they were exposed directly to similarly destructive to the smooth- lubricated coatings. the metal. Intermittent motion packer Skid plates and infeed table Ink pan, splash guard And that’s not all... Poor lubrication in buckets Friction, corrosion, clean-up Package printing plagued by Besides improving the performance stalls diaper packing problems hurt book trimming gummy ink residues of a broad spectrum of packaging One company’s intermittent motion A manufacturer of book trimming A packager was having problems machines and equipment compo- packaging machinery utilized alu- equipment was encountering friction, with its package printing operations. nents, Magnaplate’s “synergistic” minum buckets to transport dispos- corrosion, and ink and glue clean up Accumulations of gummy, half-dried surface enhancement coatings also able diapers into packaging cartons. problems on the skid plates, infeed ink at the ink pan and splash guards are recommended for a wide variety Without adequately dry-lubricated and mailer table surfaces of its trim- were causing excessive ink consump- of other equipment and machinery bucket surfaces, cartons were being mers. tion and poor reproduction. parts and components to assure effi- shorted. After Magnaplate applied one of A NEDOX coating permitted the cient, profitable production and con- The solution was a Magnaplate- its dry-lubricated TUFRAM coatings, ink which splashed on the guards to sistent product quality. applied TUFRAM coating. friction was dramatically reduced. return immediately to the pan. Clean- We offer many other Spotlight Wear problem on chutes on a diaper bagging machine is solved with a Magnaplate coating. The coating also prevented corrosion up of the guards and pan became Reports and application-specific liter- ature which detail Magnaplate sur- Heat seal and knife bars Another packager was faced with sanitary clean-up was a time-consum- and permitted quick and easy clean quick and easy and printing quality up of both the ink and the glue. was restored. face enhancement solutions. Here are Abrasive wear snags sealing bars that were sticking during ing procedure further complicated by just some of the equipment and potato chip packaging the heat sealing of polyethylene bags. the need to responsibly dispose of Aerosol valve placer machinery component solutions A large manufacturer and refurbisher Magnaplate solved the problem for spent cleaning and sanitizing solu- described in our literature: of packaging machinery was experi- the two manufacturers by coating tions. Abrasion problems plague aerosol packager Air compressor components encing severe wear problems involv- both the guides and the sealing bars By having Magnaplate apply one with PLASMADIZE. This high-tech of their food contact-approved Coin blanking dies ing sealing and knife bars used to The installation of aerosol valves is a package and heat seal potato chip surface enhancement coating features TUFRAM coatings, the creamery demanding and sensitive business. To Chrome replacement bags. The problem stemmed from unsurpassed wear resistance, excel- was able to avoid these troubling compound the challenge, one manu- Computer chip carrier handling extensive abrasive wear caused by the lent corrosion resistance and perma- problems. facturer was having problems with nent non-stick dry lubricity for all Dry ice extruder components continuous sliding of the foil chip abrasive wear on the spindle assem- Food processing discharge chutes bags over the bars. base metals. Meat packing machinery bly and disc sorter. Magnaplate was asked to apply one The PLASMADIZE coating pre- Icing problems call for A Magnaplate-applied coating of Gas blowers and exhausts of its wear-resistant, non-stick coat- vented adhesive residue build up on Magnaplate treatment TUFRAM produced a super-hard, Knives, blades and slitters ings. The result was a dramatic the guides and eliminated sticking on non-peeling surface that eliminated the heat sealing bars. The coating Operators at the Cryovac Division of Pallet loader slats improvement in wear life, as well as in the W. R. Grace Company were expe- the problem of premature wear. the parts' ability to stay free of build- also increased abrasion resistance on PET bottle molds the parts and extended their wear life. riencing vacuum-port icing problems Wear problems on the aluminum spindle Soldering equipment parts up. This helped the manufacturer on their new, high speed automated market more efficient and dependable assembly and disc sorter of this aerosol beef packaging equipment. valve placer were corrected with a Paper, film, foil converting packaging equipment. They contacted Magnaplate’s engi- Magnaplate-applied TUFRAM¨ coating. Heat sealing dies neers who recommended one of their Binding, sealing machines FDA,USDA, NSF and AgriCanada- Plastic sticking problems compliant TUFRAM coatings for the causes bottlenecks vacuum seal aluminum lid enclosures One packager was confronting a and other aluminum components. The problem with hot melt adhesive stick- harder-than-steel, non-stick coating ing to guides on a binding machine. made it possible to eliminate vacu- The problem was causing excessive um-port icing that caused a produc- machine wear and also causing bot- tion bottleneck. Vacuum sealing tlenecks in the packaging operations. speed was increased by over four times. The coating also permitted quick and easy clean-up without the use of harmful cleaning solutions

Wear, friction, corrosion and clean up ¨ On a Sealrite ice cream packaging A GOLDENEDGE surface treatment on problems on book and magazine knives, blades, slitters and other cutting machine, a TUFRAM¨ coating prevents handling and packaging equipment caustic cleaners from pitting and corroding and trimming tools increases wear life are solved by Magnaplate surface up to 20 times. the aluminum turntable holding plates. enhancement technology. Aluminum holding plate Corrosion, clean-up problems ©2002, 1999, 1994, 1992 in ice cream packaging General Magnaplate Corp. Printed in U.S.A. Before turning to Magnaplate, a 33-1002-3M creamery was having problems with 1331 Route 1, Linden, NJ 07036, (908) 862-6200 FAX: (908) 862-6110 ¨ corrosive attack on its Sealrite ice E-mail: [email protected] Web Site: www.magnaplate.com cream packaging machine’s turntable FDA, USDA, NSF, & AgriCanada-compliant General Magnaplate Texas, 801 Avenue G East, Arlington, TX 76011, (817) 649-8989 Metro (817) 640-1761 FAX: (817) 640-0860 TUFRAM¨ “synergistic” coating eliminates General Magnaplate California, 2707 Palma Drive, Ventura, CA 93003, (805) 642-6262 FAX: (805) 642-7825 Magnaplate coatings improve wear and holding plates. The caustic cleaners were causing the aluminum compo- vacuum-port icing problems on high- General Magnaplate Wisconsin, 2924 Rapids Drive, Racine, WI 53404, (262) 637-5673 FAX: (262) 637-5876 performance of heat sealing bars like speed raw beef packaging machines at General Magnaplate Canada, Ltd., 72 Orchard Road, Ajax, Ontario, Canada L1S 6L1, (905) 686-2277 FAX: (905) 686-1001 these. nents to pit and corrode. In addition, W.R. Grace's Cryovac Division. Licensees in Japan, Sweden, United Kingdom, Germany, and The Netherlands