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Weekly UpdatesConverters often promote their services as one-stop capabilities and many of them do have wide-ranging expertise. Wet wipes converting companies such as Nice-Pak Products, Rockline Industries and Tufco Technologies certainly have a full portfolio of offerings. But they are known for special strengths too. Discovering those qualifications can make a real difference to product developers.
This column will outline some of those special strengths offered by wipes converters, and you're invited to send your contributions for a Round II follow-up column. Beginning with initial converting steps, there are companies who can start the process:
Slitting-rewinding experts who know nonwovens--Being able to cut working rolls of paper and film doesn't automatically qualify a converter to cut nonwovens. Converters with expertise in this area often work with rolls directly from the nonwovens producers such as Ahlstrom, PGI and others who make jumbo rolls above 100 inches wide. The slitter-rewinder companies take the large rolls and cut them to lengths usable on wipes converting lines. While the nonwovens producers themselves can do some of the cutting to smaller sizes and some of the wipes converters handle some slitting in-house, specialty slitting-rewinding companies have capabilities that fit the needs of wipes converters. American Custom Converting and Contract Converting companies are a couple of examples in this category.
Nonwovens coating and laminating specialists--Companies who can combine nonwovens with other materials are seeing increasing interest in their services as new product ideas require laminated solutions. For example, there are possibilities of adhesive or extrusion laminations between two materials, or even three. Reasons for laminating various materials to nonwovens include creation of these properties side-to-side: Moisture barrier/soft Absorbent/repellent Stiff/soft Drapable/slip resistant White/colored Printed/unprinted Experts in laminating can target key properties while avoiding problems such as poor bond strength, inadequate wet resistance, lack of continuous seal and other pitfalls. Companies like Coating Excellence can carry out wide web extrusion coating and laminating of film, foil, paper, board and nonwovens. Larsen Converting also laminates film to nonwovens, papers and other substrates. "We also calendar nonwovens such as airlaid for a smooth, even surface," said Dan Aberly of Larsen.
On the coating side, Larsen Converting, CBC Coating and others apply additives to rolls of nonwovens. Sierra Coating's services illustrate an excellent overview of coating possibilities and need-to-know factors. "For water-activated wipes, our machines are ideally suited to apply coatings such as 'soap' or FDA accepted formulas for nonwovens," offered Robert Shade of Sierra. "In the five years we have been applying coatings to nonwovens, the interest has grown steadily, especially in the last year or so."
Sierra and other coating companies apply a metered amount so users such as janitors and other employees don't have to guess how much to apply when cleaning. Mr. Shade pointed out that it's critical to select combinations of nonwovens and additives that meet designers' objectives. For example, when producing wet wipes, the wetted product can expand. In the case of coating and drying to produce a dry wipe, the product can shrink significantly using certain nonwovens.
Printing adds value--A number of converters print on nonwovens for additional brand identification, instructional guidance or aesthetic reasons. In addition, it may be significantly more economical to make a two-sided wipe where colors indicate the difference by printing rather than coloring at an earlier stage. Companies like Tufco Technologies can print and convert wipes under one roof.
Contract converters prize trust--Contract converters are often known for their quiet work with brand product partners. You cannot readily determine who they are working with. You cannot tour and view certain production lines. Generally they do not produce their own brand and concentrate on serving brand partners. Ultimately, you can count on the confidentiality of producers such as Athea, Guy & O'Neill, Kleen Test Products, Tufco and others. In the singles category, American FlexPack is also a contract converter promoting the "fresh every time" properties of single pouch packs in cosmetics, sun care products and OTC packets.
Wipes in industrial niches--Serving industrial, janitorial, restaurant and institutional settings are dry wipes producers, many of whom have long-time experience. The list includes Atlantic Mills, Berk Wiper, Midwest Specialty Products, National Wiper Alliance, NPS Corp, Sellars and Swanson Wiper. According to Chris Plotz of ITW Dymon, "The bottom line is that wipes are a quicker, more convenient way to clean, disinfect, etc., saving precious labor dollars." Dymon's Scrubs brand line includes 22 pre-moistened disposable wipes.
Healthcare wipes grow--Some wipes converters such as PDI have been known for their role in medical and healthcare settings. PDI's Sani-Cloth germicidal disposable wipes have become a trusted surface cleaning product, and now the Sani name has been extended to consumer areas such as Sani-Hands for Kids and more. Another company known for healthcare wipes for brand partners is Triad Contract Manufacturing, with specialty capabilities for wet solution additives.
Tubs, canisters, packs--When looking for a contract partner, it's useful to know whether the converter can produce a full line or whether it specializes in certain packaging types. Product developers may choose either path, depending on product goals. For example, a niche player like Top Brass may fit needs for flat packs where it's especially knowledgeable. A converter such as Multi-Pack has strengths in supplying canisters. Athea offers strength in converting and formulating wet wipes additives. Guy & O'Neill is another formulation supplier and converts wipes. Rockline Industries offers a full line of packaging for private labeling and is especially strong in baby and flushable wipes.
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While just a brief window into the converting world of wipes, this overview also demonstrates the kind of processes and players that make up the complex manufacturing lineup in North America.
Please send idea contributions for a Round II follow-up to this column to Susan Stansbury at info@convertinginfluence.com.
Susan Stansbury can be reached at info@convertinginfluence.com.
By Susan Stansbury
Director, Converting Influence
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