Finding the cheapest liner is often the goal for a manufacturer. But what happens when a low-cost liner creates a great deal of expensive waste? That’s the problem one company was facing when it met with Loparex. The result: Loparex helped the company find a liner that while initially more expensive, has saved money by cutting waste. Loparex matched the firm with a liner that could be used multiple times and then sold, instead of being sent to the landfill.

The company had been using a very low cost polycoated liner as an in process/carrier liner for the manufacturing of a very aggressive acrylic adhesive (transfer adhesive) application.  The problem with this type of liner was roll formation, baggy web, wrinkles, all of which resulted to high waste and low yields; leading to poor service and missed deliveries to their customers.  They also had tried many times, unsuccessfully to use this liner twice in their process (flipping it and coating on the backside).

The challenge was to find an inexpensive solution that would raise their yields, drop waste, allow for reuse, and offer consistent release from a very aggressive acrylic adhesive.

Finding the Right Fit

Loparex initially suggested a 3.0 CL PET C2S (solventless 2 side) liner. The liner price was higher, but after successful reuses, the cost per use dropped and allowed this customer to achieve low waste and high yields. However, even after successfully using the liner for a few months, the customer decided that the liner cost was still too high. 

After further discussions with the R&D team, Loparex suggested a different, lower cost PET liner that could be processed through their converting equipment.  This 2.0 PET liner offered excellent layflat, great heat stability, excellent roll formation/conditions, stable release with their acrylic adhesive, reusability; all at a cost that was lower (per use) than their low cost polycoated liner. Their waste numbers decreased, yields increased and customer complaints are no longer an issue. 

With this solution in place, Loparex’ next step was to help the customer discard and/or sell the liner after they used it twice in their process. Loparex helped the company get in touch with partners who provide recycle options for odd lot, damaged and used liners so that the liners didn’t need to be sent to the landfill.

“We don’t just sell a liner for a price," says Peter Fernstrum, Loparex's Global Marketing Manager. There are many ways to bring more value. In this case Loparex looked at the life cycle of a liner and helped to explore issues like how many times a liner can be reused and what sort of recycle options exist for the used liner. "This allows the customer to get a higher value and better quality product without going over budget.”
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