“AMI Introduces NEW Adhesive Film Technology…PFA”

AMI/Industrial Division of Apache Mills, Inc. has recently developed proprietary process technology whereas we can cast solid PVC, foam PVC and composites thereof, directly on adhesive film all in a one-pass process. This process involves fusion-bonding liquid PVC to the film. Fusion bonding is the reaction of the liquid PVC solidifying and cross-linking to the film resulting in a natural, non-adhesive bond.

The adhesive package we are currently using is a rubber-based polymer with excellent tack and building-strengthover time. AMI uses a 78# heat-resistant peel-off bleached Kraft liner.

Our competitors are direct-coating an acrylic adhesive in-line at the time they are producing the PVC. The problem here is that because they are direct coating the PVC with adhesive, the PVC has direct contact with the adhesive hencethe risk of plasticizer migration. As you well know, the chemical reaction between the plasticizer in the PVC and the adhesive could cause the following problems:

• Separation between the adhesive and the PVC…
• Degradation of adhesive causing it to become “gummy” resulting in adhesive failure…

**Please note that not all acrylics prevent plasticizer migration. There might be plasticizer migration over time weakening the foam bond and/or the adhesive bond.

AMI’s technology of casting directly onto a film adhesive package provides more benefits
Or value:

• The poly film acts as a “barrier” between the PVC and the type of adhesive being used…
• Because the PVC is casted on film and fusion-bonded to the film, there will NO RISK of adhesive-to-PVC failure…
• Because there is a “barrier” between the PVC and the adhesive, eliminating the risk of plasticizer migration, AMI can use a rubber-based polymer or any adhesive system to achieve their bond-to-product success…
• Because there is a barrier fusion-bonded to the foam or solid PVC, you probably can reduce the number of mils of adhesive being concerned with the adhesion to the end product. This will in addition reduce costs of PSA.
• The poly film “barrier” also acts as a dimensional stabilizer that will increase the tear-strength of the PVC…
• Last but not least, because AMI can do this all in one pass and provide an adhesive system that is more cost-effective than the acrylic you have to use, your total cost will be significantly lower…

Why will your costs be lower? They will be lower for the following reasons:

• The acrylic PSA's you are currently using are probably much more costly than what we are using because of the threat of plasticizer migration. Make sure you add your freight to land this raw material.
• Once you receive this PSA you must then apply it to your PVC product. You will incur variable labor costs to staff and run your laminator. Depending upon the product type or sensitivity to heat and pressure, your variable labor costs will go up or down as a result of line speed through the laminator. Your costs will be even higher if you have to manually apply the PSA!
• Because you have to apply/laminate the PSA to the PVC, you will in addition incur variable overhead costs as well.
• By applying the PSA yourself, you run the risk of generating product of off-quality costs of some percentage in any process you run.
• Make sure you add in any fixed labor or overhead costs that you will incur by processing this step in your facility.

Current way:

In summary, by you utilizing a multi-step process, your costs will be significantly higher than if you purchased a complete package from AMI.

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