Moisture Barrier Coating Consumption in Food Packaging Manufacturing

Moisture barrier coatings are used to prevent moisture migration and preserve quality and shelf life of food products.

Many moisture barrier coatings are relatively thin in the order of 0.5 lbs/ream (per 3000 Ft²) or less.  These coatings can easily be measured with Near Infrared Transmitters on printed substrates to optimize the coating thickness and insure a uniform Cross Direction Web Profile.  Measurement data can be archived in roll reports that are time and date stamped for future reference in the event of customer complaints or other issues.  These reports can also be used to compare the performance of different shifts on production runs.

Coatings and adhesive need to be applied in sufficient amount to meet specifications.  Without a method to measure the deposition, many manufacturers apply more coating than needed resulting in a higher production cost.  Too little applied coating will not provide the needed barrier to prevent the migration of moisture that can result in spoilage and an adverse impact on taste, texture and shelf life.

Stopping the line to collect lab samples slows production and does not supply archiving capabilities for roll or production runs.  On-line continuous measurement of coating speeds start up, increases production and in-specification product.

The wet water based coated substrate typically passes through a dryer and then a re-moisturizer where a separate moisture measurement system supplies the output to control the moisture profile and minimize or eliminate lay flat and edge curl issues.

Plant managers are often concerned about coating consumption which impacts the profit margin on specific orders.  Coating calculations determine the amount needed for a specific product run and the cost of coating associated with that product run.  For instance, if a 40 inch wide web with a target of 1 wet lb per 1000 ft squared and an anilox volume of 14 BCM is being manufactured, both the weight in pounds and volume in gallons can be calculated.  If the web width for another version of the same product is increased to 80 inches, the consumption significantly increases but it is not a simple doubling of necessary coating as that is a function of increased area not simply web width.

Near Infrared technology employed on-line can calculate the continuous consumption to aid in monitoring the production run or roll consumption when incorporating other parameters.

Please contact us to discuss your application today at 508.473-9901.

 

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