To redevelop a customer’s existing construction, but having to use alternative adhesive systems and carrier.
A customer had an existing construction manufactured by another coater, they came to us wanting us to make the same construction for them. However, they didn’t know the supplier of the raw materials used in their existing product (often this is the case as coaters keep it a mystery from their customers).
The requirements they had for this product included meeting both the performance and the price targets of their existing product, as well as undergoing all stages of the trial, testing and manufacture in a cleanroom environment.
To find replacements for each element of the existing construction, we had to test each of the component parts individually. We also had to source raw materials that met the exacting medical qualifications required.
The process took around 12 months in total; most wound care developments take around 12 months to 2 years to complete, however our flexibility meant that we were able to complete the project as quickly and efficiently as the customer required us to. Our work with this customer involved a lengthy period of intricate lab testing, numerous pilot line trials and full production qualification work. Throughout each stage of this process we worked very closely with the customer to ensure that feedback was understood and that the products adapted to satisfy changing performance requirements.
The customer was extremely pleased with the speed of response to their enquiry and the high standard of quality support that they received throughout both the pilot line trials and full production manufacture stages. They were also very happy with how the new product performed in the same way that the existing product did.
Specific release characteristics were needed for a customer’s tri-laminate construction for the next stage of manufacture (conversion and lamination) to be possible.
To solve the customer’s challenge we needed to figure out the relationship between the release liner, the release value and the acrylic PSA. Why? Because not understanding this relationship between the different elements of the construction would make the conversion process impossible.
There were two key areas to this development work. Firstly, testing: Our lab technicians took on the laborious task of testing materials and constructions with just one small change at a time. This slow, methodical way of testing gave our technicians a detailed look at the impact made with each change. Secondly, sourcing: Our knowledge of and experience with adhesive and liner suppliers meant that we could outsource alternative materials that better matched the requirements of the customer’s specifications.
The flexible way in which we work was a real advantage to the customer, as it meant we could do short runs on both the pilot line and the main line to validate the product as smoothly and as quickly as possible. Our partnership approach was also a big part of the validation process; working closely with the customer, we were able to make a number of iterations to get the construction to where both the customer and ourselves wanted it to be, without delaying the targeted completion date.
The feedback we received from the customer spoke of how they were impressed with our speed of response and also our ability to give them the end product they required.
Julian Watkins | Business Development Manager
Raleigh Hall Industrial Estate, Eccleshall,
Staffordshire, ST21 6JL, England
+44 (0) 1785 850 357
+44 (0) 7738 217984