The future of adhesion. The (perhaps) only way to green surface treatment

Already now, sustainable initiatives are knocking on the door of manufacturing companies. With scope 1, 2 and 3 reporting breathing down companies’ necks, the green transition of production lines has received new attention from boards, management and of course customers. And even though the development is welcomed by most, it’s no secret that production managers around the world are scratching their heads when they look out over the production line.

Eco-friendly production is about many things. Much more than can be covered in a single article, yet here we address one of the biggest reasons: the surface treatment of materials that need to be prepared for adhesion.

When we talk about surface treatment, we’re talking about processes that traditionally involve harsh chemistry, dangerous techniques and considerable CO2 emissions. But we also address an another-known alternative to surface treatment that solves practically all the problems, plasma and corona technology.

Risky coating methods fall short in sustainable production.
When we look at surface treatment methods, there have traditionally been two options: flame treatment or chemical treatment. And while these two methods have solved the problem of poor adhesion to an acceptable degree, it’s also clear that they have significant environmental disadvantages.

Flame treatment, as you know, involves the use of open flames, which of course requires the combustion of fuels. This results in the emission of harmful substances such as CO2, carbon monoxide (CO), nitrogen oxides (NOx) and volatile organic compounds (VOCs) that worsen air pollution and contribute to climate change. Flame treatment also carries the risk of serious occupational accidents as handling open flames and flammable materials creates an unsafe working environment – even though many manufacturing companies have installed flame treatments on robotic arms.

If we look at the chemical alternative to surface treatment, it is in many ways even more problematic.

This method usually requires a wide range of chemicals, which are often toxic and harmful to both the environment and human health. The release of these chemicals can cause serious water and soil contamination, and exposure to them can have health consequences for your employees. To add insult to injury, the management and disposal of chemical waste is both costly and regulated by strict environmental laws, increasing overall operational costs.

Neither align with sustainable manufacturing, in other words.

So, despite the fact that the two predominant technologies for surface treatment of materials solve the adhesion problem, they are far from harmonizing with the need for sustainable production in terms of economic, environmental and occupational sustainability. This is where plasma and corona coatings come in as a revolutionary solution.

The surface treatment of the future: sustainable on all levels
It may sound like a sales pitch from the hot countries, but the fact is that plasma and corona surface treatment represent cutting-edge technologies that not only solve environmental challenges, but also contribute to a more fluid and efficient production line.

Plasma treatment works by applying an ionized air that activates the surface of materials such as plastics, rubber, composites and metals. This process removes impurities and increases the energy of the surface, improving the adhesion of coatings, glues, paints and coatings.

Corona treatment is similar in concept to plasma, but instead uses a powerful electrical discharge to create a reactive surface, which in turn significantly increases adhesion properties.

In other words, both plasma and corona fully solve the adhesion problems.

One of the most notable advantages of these technologies is their ability to operate without producing harmful chemicals or requiring high temperatures. This not only reduces environmental impact, but also improves the working environment by eliminating exposure to hazardous substances and minimizing the risk of workplace accidents.

The non-invasive nature of plasma and corona treatment also means there is no physical contact with the material, preventing damage and ensuring consistent results every time – something neither flames nor chemistry can do without.

When environment and economy go hand in hand
The benefits of plasma and corona treatment don’t stop at environmental and occupational safety. Both technologies are easily integrated into existing production lines, either on a robotic arm or inline, and can be performed at high speed, making them ideal for industrial applications where efficiency and precision are vital.

The technology’s ability to quickly treat large surface areas without the need for frequent maintenance or downtime means your production line can run more smoothly and with fewer interruptions. By improving surface adhesion properties, both plasma and corona technologies also reduce the need for repeated treatments, resulting in higher quality and more reliable production.

By switching to plasma and corona technologies, you can drastically reduce your company’s environmental footprint, improve the working environment and at the same time achieve more efficient and economically beneficial production. It’s sustainability in action – a win-win situation for both your business and the planet.

Competitiveness is being ahead of the curve.
Let’s be honest: Technological development in a sustainable direction is no longer an option – it’s a necessity. Companies that ignore this inevitable reality risk being left on the sidelines as competitors roar past.

When making decisions about the future of manufacturing, think about the big picture and realize that sustainability isn’t a fad; it’s the foundation for long-term success. To stay relevant and competitive, you need to be able to adapt and stay ahead of sustainable innovations, and plasma and corona coatings represent just that kind of innovation.

So, ask yourself: Are you ready to take the leap into the future?

It’s time to act. The future won’t wait.