The packaging industry is perpetually in motion, with materials, production techniques, and global standards continually evolving. In response to these shifts, thyssenkrupp Rasselstein is strategically repositioning its expertise in surface technology to align with future industry demands. The Technology, Innovation and Quality division, encompassing the Surface Technology and Chemistry department, plays a pivotal role in executing this strategy. “Our department’s expert teams are integral to every critical process, ranging from the development of innovative products and enhancement of existing surfaces to the certification of our tinplate. In addition, we actively contribute to work within European associations,” states Tobias Kirst, Head of Surface Technology and Chemistry (Oberflächentechnik und Chemie, OTC) at thyssenkrupp Rasselstein.
The primary aim of OTC’s development efforts is centered on optimizing the surface of packaging steel. The department’s diverse expert teams collaborate closely with Technical Customer Service, Production, and Sales to enhance the fulfillment of customer needs. By consolidating innovative expertise within specialized teams and establishing cross-sector technology networks with value chain partners, opportunities for advancement are leveraged more effectively. The department is organized into five expert teams, each focusing on distinct areas of responsibility: Analytics, Product and Production Support, Conformities, New Surfaces, and Organic Coatings with Lacquers or Film.
In the packaging industry, innovation distinguishes leaders from followers
The Analytics expert team primarily focuses on measuring values critical to the production of packaging steel, including data related to the water cycle. These values help ascertain whether all production parameters are correctly adjusted. Additionally, Analytics is an integral part of quality assurance, encompassing production monitoring tasks such as overseeing the electrolytic coating processes of the coating lines and all production bath concentrations. This expert team collaborates closely with the production support department to address customer queries about packaging steel processing. “From the customer’s perspective, it’s not always clear which external factors might affect the material. Once our team identifies the cause, we join forces with the support team to devise solutions that enhance the customer’s production processes,” explains Tobias Kirst.
In the packaging industry, innovation distinguishes the leaders from the rest. Consequently, thyssenkrupp Rasselstein places a strong emphasis on ongoing research and development, broadening its collaborations with universities and research institutes. The goal of these partnerships is to create products that are sustainable for the future, thereby providing long-term benefits to manufacturers and fillers. For instance, the OTC division is currently developing an alternative to traditional rolling oil. Collaborative research efforts are underway with the renowned Fraunhofer Institute to achieve energy efficiencies in tinplate production, as well as with other research bodies focusing on bipolar plates for fuel cells, contributing to the energy transition.
Prompt evaluation of new regulations
The role of regulation is becoming increasingly critical for surface technologies. Swift response times and a proactive, solution-focused approach are crucial, as recently demonstrated by the 2021 ban on perfluoroalkyl and polyfluoroalkyl substances (PFAS) by the U.S. Environmental Protection Agency (EPA). “Customers need to trust that manufacturers will respond swiftly and adeptly to regulations that are implemented unexpectedly, whether it’s a ban on substances or adjustments to compliance limits. This is equally true for the adoption of the chromium-free passivation alternative (CFPA) for tinplate and TCCT® as a REACH-compliant ECCS. In these and similar situations, we have proactively taken the necessary steps to ensure uninterrupted production. Consequently, the OTC division is deeply engaged in industry association efforts to promptly understand regulatory changes and their implications for the packaging sector," states Tobias Kirst.
At thyssenkrupp Rasselstein, the “Conformities” and “New Surfaces” expert team members are dedicated to overseeing sensitive material properties and ensuring product stability. They meticulously ensure, for example, that only certified packaging materials are utilized for coils to prevent any contact with hazardous substances. Additionally, the longevity of new surface treatments undergoes thorough evaluation through storage tests. In these tests, tinplate cans filled with food are stored for periods of 12, 24, and 36 months, after which both the filling good and the packaging are examined for any potential alterations.
One of the expert teams at thyssenkrupp Rasselstein specializes in coatings and films, recognizing their growing significance in combination with tinplate. Despite the company not manufacturing coatings or films itself, thyssenkrupp Rasselstein is deeply invested in this area. “We collaborate closely with suppliers and customers to ensure the delivery of thoroughly vetted and entirely safe products to consumers. This requires a perfect alignment among the can, its coating, and the filling good,” Tobias Kirst explains regarding the initiative. The coating's barrier effect is crucial; it must maintain specific porosity levels and demonstrate high stability. In this regard, the Surface Technology and Chemistry team’s expertise was recently sought in developing the chromium-free passivation alternative CFPA. The suitability of BPA-NI coating generations for chromium-free passivation was evaluated. Findings indicated that CFPA, with its higher surface energy compared to chromium-based passivations, offers improved wettability, making them ideally suited for transitioning to BPA-NI coatings.