Easytech Packaging has worked with Henkel Adhesive Technologies to stabilise aluminium can-end production for the pet food market following the introduction of new equipment and a PVC-free coil coating.

The company, based in Fisciano, southern Italy, invested in four high-speed rotary liners after securing a major order from a leading brand manufacturer. The project combined equipment changes with a move into aluminium can ends and a customer requirement for a PVC-free coating.

Easytech had extensive experience processing steel but had not previously produced aluminium can ends. Aluminium’s different behaviour during forming and coating added complexity to the project.

“This contract has enabled us to access this entirely new market,” says Dr Fabio Bove, General Manager of Easytech. “The requirements in terms of sealing properties, food safety and process stability are similar but, in some respects, even more complex than those of the human food industry. At the same time, production speeds and material combinations are more demanding. In order to satisfy all these requirements, we had to fundamentally modify our processes.”

According to Henkel, initial trials revealed problems with forming and coil lubrication, as well as the application of its water-based sealing compound, Darex WBC 733 PHV.

Accurate compound placement proved difficult on the high-speed rotary liners. Their closely spaced application nozzles meant that even minor adjustments at one position affected neighbouring positions, altering pressure conditions and compound distribution. This complicated equipment adjustments and initially produced inconsistent results.

The interaction between the PVC-free coating and coil lubricant also intensified dewetting, causing the compound to shrink in places and develop holes. These defects increased rejection rates and reduced production efficiency.

“Introducing new equipment, a new substrate, and a new raw material for the cans and lids all at once was a major challenge,” says Giuseppe Scarola, Operations Manager at Easytech. “That’s where Henkel’s experience really made the difference. Their experts guided us through every test phase – on site and remotely – until we reached full stability in production.”

The companies tested filling volumes, analysed compound viscosity under different production conditions and adjusted equipment and application parameters.

Henkel identified insufficient compound homogeneity as a factor affecting distribution accuracy. Easytech installed a new stirrer on Henkel’s recommendation, improving homogeneity and significantly reducing dewetting. The coil supplier also adjusted relubrication to minimise interactions with the sealing compound, while Easytech modified internal processes to stabilise application conditions.

Henkel provided training on running the compound on the rotary liners and supported equipment adjustments. Series production began after six months.

“The most valuable part of this story is the relationship we’ve been able to build throughout the project,” says Fabio Lanaro, Regional Key Account Manager Metal Packaging at Henkel. “We supported Easytech both remotely and on site, analysing every detail together until the process was fully stabilised and the customer’s requirements were met.”

According to Henkel, production has subsequently run stably on all four rotary liners for more than 12 months. The compound is being applied reliably and evenly, rejection rates have fallen considerably and the customer’s requirements have been met.

“Looking back, the key to success was not a new product or new equipment but the knowledge of how to make everything work together,” Giuseppe Scarola says.