From technical evaluation to production-ready solutions — with KCL
In an environment of rising raw material and energy costs, potential savings can be found in coating structures and drying operations. However, reducing coat weight or modifying pigment and binder systems can carry technical risks. These risks can be avoided through thorough testing. KCL can support in systematic cost optimization projects and accelerate the transition from development to full-scale production implementation.
By outsourcing routine cost optimisation testing and technical evaluations to KCL, you can benefit from a high-quality, systematic approach that minimises the risks associated with mill-scale implementation. Outsourcing the project is cost-effective because it keeps the lead time short. Internal debates and competing priorities often cause projects to take much longer. The quicker you implement cost savings in production, the more you can save.
Structured evaluation and development approach
Each project starts with a technical baseline evaluation of the current product and process. Coating formulations, coat weights, application methods, drying conditions, and print quality requirements are reviewed to identify performance margins and key cost drivers. This creates a fact-based foundation for defining realistic optimization targets.
At laboratory scale, KCL screens alternative coating color formulations. Pigment blends, binder ratios, and functional additive can be optimized while maintaining coating rheology, water retention, and runnability. Surface properties such as roughness, porosity, gloss, and absorption can be characterized alongside with print performance indicators.
Promising solutions can then be validated in pilot-scale coating and printing trials under industrially relevant conditions. These trials allow verification of coat weight reduction strategies, optimization of coating layer structures, evaluation of drying efficiency and energy demand, and printing trials using relevant techniques such as offset and flexo. Pilot-scale validation significantly reduces uncertainty before mill-scale trials.
Support in mill-scale production implementation
To accelerate implementation, KCL supports customers during mill-scale coating and printing trials by providing technical recommendations, assisting with parameter optimization, and analysing post-trial quality, cost, and process stability. This ensures that development results translate into measurable and sustainable cost savings in production.
Why KCL?
KCL offers independent, science-based expertise supported by advanced coating and printing laboratories and industrial pilot-scale equipment. By combining material science, process understanding, and print performance evaluation, KCL enables reliable cost optimization of coated paper and board packaging grades — while minimizing industrial risk and accelerating time to production.
For more information, contact:
Mikko Mensonen, Head of Coating, Printing, Finishing
mikko.mensonen(at)kcl.fi
+358 40 522 6005