Focusing release paper
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First, the market articles
1. Global release paper market
In the market for pressure sensitive labels, the release paper supply chain faces a number of threats and cost issues. However, there are still opportunities in this area.
Globally, the market for release papers (known as bottom papers) is now very active. Although it still exists as an “inevitable evil” in many areas, it is because it occupies a high percentage of the cost of pressure sensitive labels – typically 20% to 30%. As the world's attention is focused on environmental sustainability, the need to build a strong work platform for the reuse and recycling of release paper waste is becoming increasingly urgent. Thanks to pioneering efforts like Mr. Calvin Frost of Channeled Resources Group of the United States, the problem of reproducibility of release paper has been largely solved; at the same time, the release film is extremely simple by functional regranulation. Use the route.
Label material: the main market for release paper
As shown in Figure 1, the global production of release paper is 30.5 billion square meters. From the regional perspective, North America accounted for 37.4%, Europe accounted for 30.3%, Asia accounted for 24.0%, and the rest of the world accounted for 8.3%. From the application field, label materials accounted for 49.7%, tape accounted for 14.1%, and industry accounted for 9.3%. Health accounted for 6.7%, image art accounted for 6.1%, medicine accounted for 2.8%, envelopes accounted for 2.3%, others accounted for 9.0%; from the material point of view, calendered kraft paper accounted for 43.8%, clay coated paper accounted for 16.1%, polyethylene coating Paper accounted for 15.7%, film accounted for 15.4%, and other papers accounted for 9.0%.
In many industrial applications such as tape, medical and envelopes, and release papers, label materials remain the main market for global release paper, accounting for about 50% of the market share, with an annual growth rate of 9.9%. In the label material market, although the quality and function of the release film are greatly valued, the release paper - calendered kraft paper, glassine paper (also known as translucent cellophane), clay coated paper, polyethylene coated paper And other grades of materials still account for 85% of the bulk of the application.
Calendered kraft paper continues to enjoy a majority share of the market of approximately 44%. However, there is no doubt that we are seeing the largest increase in release film, which may be limited only by the cost of raw materials.
As shown in Figure 2, the percentage of release paper used in various label fields in the world in 2006 was: glue applied labels accounted for 50%, pressure sensitive labels accounted for 40%, shrink sleeve labels accounted for 7%, and in-mold labels accounted for 7%. 2%, other tags account for 1%.
Challenges from rising material costs
Today, rising material costs are a key issue for the entire label industry, and raw material costs have risen to record highs, especially for petrochemical-related products, with no solutions in the short to medium term. This is causing a domino effect in the supply chain, from raw materials and chemical suppliers to silicon paper processors and laminate producers to label processors and end users, all of which are under pressure to reduce profit margins. At the same time they are actively seeking ways to reduce costs.
The result is an increasing interest in reducing the standards for release paper materials (this not only saves on material costs, but also reduces downtime for processor equipment and end-user label distribution lines through longer rolling times) ). Release papers and release films are the focus of attention in this regard, and even a small drop in material standards can mean worth the cost savings. Low-platinum release paper coatings are also a focus of attention.
Technical Challenges - Release paper manufacturers face a number of technical challenges in the search for low-standard, high-performance materials that include not only base materials, but also silicone coatings. We are seeing signs of growing supply chain partnerships between silicon paper processors and silicone suppliers and release liner and release film suppliers to find cost-effective and innovative solutions.
The threat of linerless paper - no release liner label material is now a point of interest. Label material laminates have come up with a viable solution to make technology go beyond on-demand printing, simply cutting the shape of the label, which will bring real change to the label market.
However, since variable information tags are used in the logistics, retail, and transportation sectors rather than in the main product areas, it is important to remember that pressure sensitive labels enjoy a significant market share. In the variable information printing arena, no release paper labels are undoubtedly threatening.
RFID and other smart technologies may represent a strong development market for pressure sensitive label materials. However, even if they are fully commercialized, it is impossible to replace other traditional tracking tools such as barcodes. Other alternative product identification and decoration methods are also robbing the market share of pressure sensitive labels in major label applications. In-mold labels, shrink sleeve labels, and direct printing are techniques that make release paper useless.
New opportunities for processors
A development in the field of release paper is directly related to label processors and has generated great interest at the European Label Show held in Brussels in September 2007. On-line label material lamination technology for short-term professional applications has been around for a while, and it is now commercially available to make this feature a higher level of print and quality. For processors, this represents a good opportunity to control costs and maximize profits without the need for “intermediaries” – pressure sensitive label laminators. This is also an opportunity for release paper suppliers to develop new business platforms.
As brand manufacturers continue to increase the same brand's taste, smell and other changes, the number of copies is becoming less. Narrow web label printers should be properly positioned to take advantage of this trend, especially for label processors who can also laminate pressure sensitive labels themselves.
The future: adding value
Label release paper and label release film can expect their role to increase, essentially adding value in the label production and distribution. But because of the cost of today, changes in the rules of the game must be included in the producer's agenda.
2. The radiation curing release coating market is developing well
The market for radiation-curing release coatings is in a healthy state of development, and rising energy costs make its applications more attractive.
Silicone acrylates and silicone epoxies used in the production of release coatings are no longer a new technology. The use of both resins has become rock solid in the pressure sensitive tape and label market, and even in the production of major labels. However, most of its growth still exists in niche areas such as professional labels and integrated business forms; at the same time, their growth is good, and due to professional characteristics, this situation is expected to be maintained.
Most recent changes in the industry are related to company adjustments. Among the major North American market participants, GE Silicone's products became part of Momentum; Rhodia's products now belong to Bluestar; Degussa is now part of the Evonik industry.
The focus has actually turned to the inside of the enterprise: trying to control costs while being squeezed by both ends (higher raw material costs and processors' demand for low-cost products). A key element (increasing value) becomes the essence of the production process in order to make the production process more efficient.
Increase value
The survey is based on the search for new oligomers that can be produced more efficiently, but still with the quality required by the industry. Finding better and more efficient photoinitiators/catalysts is also a key area of research.
Silicone suppliers are already working with other suppliers to make technology a turnkey service with operator-friendly features. Equipment with system integrated coating and curing, including the inerting unit required for acrylic systems, is now available on the market. Substrate (paper and film) suppliers have paid attention and are now able to offer products that are more suitable for radiation curing reactions. One of the attractions of radiation curing (especially acrylic systems) is its ability to increase the value of the final formulation. It is now required that release coatings not only protect and release pressure sensitive adhesives, but new self-wound products require release coatings to be a functional part of the finished product. They can be modified with the material to adjust the gloss, color and hardness of the finished coating.
This new product has emerged as processors are trying to add value to their products. Radiation-cured silicones make it easier, allowing the use of thinner or less heat-resistant substrates, making the application of release-free paper easier to achieve. The equipment required for radiation curing has enabled this technology to be used in the narrow-width rotary industry and gives label processors more control over product design and quality.
North America and Europe continue to see good growth in release coatings in the professional sector, but the effectiveness of turnkey equipment has helped to open up markets in new regions, especially in Asia and South America. At this time, the investment has become easier because the “old technology” is no longer used.
Price is too high
A key barrier to preventing the growth of radiation curing is "too expensive", which is based on the higher cost of silicone. But the industry's goal is to guide users to the overall technology cost – materials, equipment, waste, etc. In particular, rising energy costs have made the use of radiation curing even more attractive.
The radiation-curing silicone industry is full of vitality. As the market requirements change, new modified products continue to be introduced. Suppliers and equipment manufacturers have contributed to making it a successful adventure.
Second, the case articles
Confident release paper manufacturer
Itasa, located in the “Paper Valley” of the Basque region of Spain, is an independent manufacturer of coated release paper and a major commercial silicon paper processor in Spain. The company's high-quality release papers are known for their high performance, especially in the self-adhesive and specialty tape industries and medical disposables.
The demand for quality reputation has caused Itasa to invest 16 million euros in new equipment, especially a new coating machine from Bachofen + Meier (BMB), which is now in the start-up phase if the equipment is fully operational Will make Itasa's production capacity double now.
Family business
Itasa is a privately owned company founded in 1974 by two local families. Its initial goal was to meet the needs of two professional end-use departments for silicon paper: personal hygiene and backing as a Formica brand of surface finish products.
Since Itasa's target market was once limited to its hometown, the area received was poorly supported and the company first used home-made coating equipment for production. However, when Spain joined the European Union in the late 1980s, Itasa's management team saw significant development opportunities in the “common market”. In order not to miss these opportunities, the company decided to plant, technical knowledge and personnel. Increase investment.
Today, Itasa has 80% of its products exported, 50% of which are sold to Europe and the remaining 30% to the US, Latin America, Mexico, Asia and Oceania. However, in the era of globalization, Itasa decided to adhere to a business strategy that enabled the company to adhere to its ISO 9001-approved production in one location while expanding sales in selected key markets around the world.
Superior geographical environment
Mr. Francisco Pagola, General Manager of Itasa, said: “We are located in the northwest of Spain and it is an ideal location from a logistics perspective. We are close to the northern port of Spain and the south of France, and closer to the Transcontinental Airline.”
As demand increased, Itasa installed the first roll-to-roll coater in 1989. The new coater is 1.65 m wide and relies on a five-roll calendered coating head and air floating dryer for a production speed of 500 m/min. It features a web cleaning device, an electrostatic discharge device, and an online trimming device. This coater handles paper, film and heat-sensitive webs, and is free to choose UV curing and corona treatment, as well as make imprints online.
Significant investment decision
Even with this heavy-duty equipment as the protagonist of production, Itasa's production capacity has reached saturation point in the past two years. Emilio Arocena, the company's chief financial officer, said: "If we want to remain competitive and profitable, we must increase our investment to achieve cost savings and productivity gains in a wider web coating. At the same time, it will not damage our high quality standards. That is why we ordered a custom-made 2m wide new BMB coater."
Coating machine that meets the latest technological development level
This tailor-made new BMB automatic web coater is 2.3 meters wide and can be coated 800 meters per minute. It has many advanced features, including Pesmel web automatic paper feeding device capable of handling up to 5 tons of paper rolls, a web cleaning system, active and passive electrostatic discharge devices, anti-fog devices, online cutting Edge and paper slitting device. Its core performance is a five-roll calender coating head that can be converted into a six-roller for thermosetting, solvent-free silicone coating. It has a 28 m long, 7-part drying tunnel that operates on an air floating system; two web re-wetted steam boxes (with steam-adjustable characteristics); and a set of chill rolls. The coater also has the flexibility to coat different widths of 1.1 meters and above and is supported by an advanced automatic silicone mixing device.
High-speed coating of various types of release paper can be used for papers with a weight of 30-200 g/m2 (kraft paper, polyethylene coated paper, clay coated paper, single-coated paper, double-coated paper). With the same or different release paper characteristics, suitable for a variety of applications such as tape, label materials, industrial and composite, as well as envelopes and self-adhesive image art.
Surface finishing and warehouse storage
An online new paper cutter will support the new coating equipment and an additional surface finisher is being ordered.
The installation of a new wide-format coater has created a serious space problem for Itasa. The new equipment occupies most of the warehouse space where raw materials were previously stored.
Meaning for the future
José María Pagola, Export Sales Manager of Itasa, summed up the proceeds from this major investment: “This new coater gives us a real competitive advantage through speed and productivity improvements. With additional surface finishes that are already in preparation and The warehousing system, we are able to locate accurately, like a person without any constraints, can seize new business opportunities in the current industry consolidation trend, and the merger will make buyers need to make alternative choices for suppliers."
“We see that the core markets we serve are in a sustainable and healthy development in the medium term, especially in the label market. In the long run, there will undoubtedly be a new terminal market emerging through innovations in lamination and liner technology. There is enough evidence to prove that the silicon paper market has great potential."
Successful mode
Itasa's management team is passionate about the future possibilities of wide-format coating and surface finishing equipment that is effectively operated by equipment supervisors trained in the paper industry. The production facility is suitable for demanding professional manufacturers of release papers, which are kept extremely clean and tidy, and are continuously produced in four shifts a day, 24 hours a day, four days a week. Lab staff have the same working hours for real-time quality analysis and feedback to the production team.
With a total of 70 employees, Itasa is well prepared to tap the potential of selected markets for the foreseeable future.