Live Webinar: Exploring End-to-End Coating with Powerdrop at Archipelago Technology

On October 2nd, join us for a live webinar: Exploring End-to-End Coating with Powerdrop at Archipelago Technology

In anticipation of this event, Elena Knight from FuturePrint spoke with Lekshmi B.S., a PhD scientist at Archipelago Technology about her background, her role at Archipelago, and how Powerdrop is transforming sustainable packaging solutions.

Elena: Lekshmi, can you start by telling us a bit about your background and how you came to work with Archipelago Technology?

Lekshmi: Certainly! I have a strong academic foundation in physics, having completed my Ph.D. at the National Institute of Technology in Calicut, India, with a focus on high-speed imaging techniques. Prior to that, I earned my M.Sc. and B.Sc. in Physics from the University of Kerala. My journey through academia provided me with deep insights into material sciences and imaging processes, which naturally led me to the innovative work we’re doing here at Archipelago Technology. I now use my background to help develop and refine our "End-to-End Coating with Powerdrop" solutions for sustainable packaging.

Elena: You’re part of the "End-to-End Coating with Powerdrop" team at Archipelago. Could you explain what that’s all about?

Lekshmi: Of course. Archipelago offers an end-to-end solution based around Powerdrop, which helps coat paper and fibre-based packaging to make them waterproof and oilproof. Our goal is to address the massive issue of plastic waste by providing a sustainable alternative that still offers the protective qualities of plastic. What makes Powerdrop unique is its ability to apply coatings without pinholes, ensuring complete protection while maintaining recyclability.

Elena: Can you give an example of how Powerdrop works in real-world applications?

Lekshmi: Absolutely. For example, say a customer wants to create waterproof makeup containers made of paper. They would come to us with their product, and we would take it through our entire process—from coating to final testing—using industrially proven liquids. Before the system leaves Archipelago, we ensure the entire process is demonstrated to the customer, giving them a market-ready product.

Elena: What specific challenges does Powerdrop solve in today’s packaging landscape?

Lekshmi: Globally, 150 million tons of plastic packaging are used every year, and only 9% of that is recycled. The rest is either incinerated, buried, or thrown into the ocean. Paper-based packaging, on the other hand, is sustainable and recyclable, but it’s not naturally waterproof. Powerdrop technology enables paper and fibre-based packaging to become waterproof and oilproof, while still being recyclable through conventional shredding and pulping technologies.

Elena: You mentioned the term "pinhole-free coating." What does that mean, and why is it important?

Lekshmi: A pinhole-free coating is crucial because it ensures a uniform, continuous surface that prevents any liquid penetration. We’ve developed four golden rules at Archipelago to achieve this:

1 - The coating liquid should wet the substrate: This ensures that the coating properly adheres to the surface and spreads evenly across the material.

2 - The viscosity of the coating liquid should be less than 200 mPa’s (millipascal seconds): A lower viscosity allows the liquid to flow smoothly and form a thin, even coating on the substrate.

3 - The droplets should coalesce to form a uniform thin coating: This prevents gaps or "pinholes" in the coating, ensuring full coverage and effective waterproofing.

4 - The coating should stay on the side walls of 3D containers: For packaging with complex shapes or 3D structures, it's crucial that the coating remains intact even on vertical or angled surfaces.

By following these guidelines, we ensure that our coatings not only protect but also maintain the recyclability of the packaging.

Join us on October 2nd for the live webinar to hear more from Lekshmi & her Archipelago colleagues and learn how Archipelago Technology’s Powerdrop solution is creating opportunities for more sustainable packaging options. This is your chance to ask questions and explore how this innovative technology can benefit your business.