Cost-effective, material-saving, local – Ultrathin Coating enables sustainable production of medical protective clothing

We all remember the beginning of the Corona pandemic: the demand for medical protective clothing increased rapidly, leading to supply bottlenecks. Although the situation has calmed down again, the dependence of companies on global supply chains was exposed. Reifenhäuser is now specifically addressing this problem with its new Ultrathin Coating process.

In an interview with K-MAG, Mark Borutta talks about how film/nonwoven composites can be produced cost-effectively, in a material-saving manner, locally and thus more environmentally friendly thanks to the new process.

Mr. Borutta, what problems do you currently see that have created the need for new production processes?

Mark Borutta: One major problem so far has been the cost pressure to keep local production competitive with imports. Another driver for the development of new production processes is the sustainability shift and the associated requirement to reduce the use of materials – especially for disposable products.

To what extent can the Ultrathin Coating process you mentioned solve these problems?

Borutta: With our new Ultrathin Coating process, producers achieve a significant reduction in coating grammage. This reduces the amount of material used, which correspondingly reduces material costs and enables competitive local production. In addition, we save fossil raw materials and CO₂ emissions and obtain a more sustainable product overall.

The special feature of the process is that despite the reduction in grammage, the properties of the end product remain the same. The significant cost savings are achieved, among other things, by dispensing with hotmelt adhesives, while at the same time guaranteeing the adhesion of the film/nonwoven composite.

You cooperated with your sister company Reifenhäuser Reicofil for the development. What was the advantage of this?

Borutta: Our sister business unit is a leading global manufacturer of nonwovens lines and in particular has in-depth knowledge of the substrate to be coated (nonwoven) as well as special know-how in the medical and hygiene sectors, where the main applications for nonwovens and film/nonwoven composites are located. Being able to draw on this expertise within our own group of companies is of course a decisive advantage, from which the customer ultimately benefits.

You have just mentioned an advantage for the customer. In your opinion, why is it worthwhile for processing companies to invest in the new process?

Borutta: The dependence of companies on global supply chains was exposed by the Corona pandemic and supply shortages. As a result, there is a trend toward local production – at least as a backup. Due to the cost advantage of the Ultrathin Coating process, processors can now build a profitable business. The investment usually pays for itself in less than twelve months.

To what extent is this a step towards a sustainable plastics industry?

Borutta: An effective adjusting screw for making the plastics industry more sustainable – especially in the area of disposable products for medical and hygiene applications – is the use of materials. With Ultrathin Coating, we drastically reduce the consumption of fossil resources and at the same time reduce the amount of waste. Raising this potential across the board is a big step in the right direction.