Easytech and Henkel, process stability and quality on PVC free coils for the Pet Food

Introducing new materials and technologies rarely comes without obstacles, especially in the field of metal packaging for food applications. Easytech Packaging, one of the world’s leading manufacturers of ends and bottoms for metal cans, faced this challenge when entering the Pet Food market with a project that demanded a substantial reorganisation of its processes.

The company, based in Fisciano and acting as Silgan Holdings’ European centre of competence for Easy Open Ends, adopted aluminium coils with a completely PVC free coating, combined with new rotary lines capable of producing up to 1,200 lids per minute.

The shift to a substrate never used before, together with the high performance required by the sector, immediately revealed unexpected criticalities. Initial trials showed quality issues both in forming and in the application of Henkel’s Darex WBC 733 PHV sealant, with “dewetting” phenomena and difficulties in achieving precise placement. The interaction between the new coating and the coil lubrication made process fine tuning particularly complex, increasing scrap rates and putting production stability under strain.

Collaboration with Henkel Adhesive Technologies proved decisive. The company’s specialists supported Easytech throughout every phase, analysing parameters, viscosity, operating conditions and material interactions. A key step was the redesign of the sealant mixing system, which enabled a more homogeneous structure and more stable distribution. At the same time, coil lubrication, rotary unit settings and internal process parameters were optimised, while dedicated training sessions helped operators manage the new equipment effectively.

After six months of joint work, production was launched with full stability and, for more than a year, the four rotary lines have been running smoothly, with scrap drastically reduced and consistent quality. The Darex WBC 733 PHV sealant is now applied uniformly and reliably, ensuring compliance with the requirements of both the customer and the Pet Food market.

The added value of the project lies not only in the technical solution but also in the collaborative approach adopted. Easytech and Henkel built a relationship based on continuous dialogue, on site support and shared expertise, transforming a complex challenge into a path of mutual growth. This approach continues today, supporting rising production volumes and consolidating a partnership focused on quality and process sustainability.