A leading carbonated beverage company approached Bolger & O’Hearn Inc. about the possibility of developing a thin film insulative coating that would keep a beverage in the optimum drinkable range for longer. The company was looking for a competitive advantage in markets where electricity and refrigeration were not reliable.
The beverage company had generated a proof-of-concept by laminating different foams to their label. The insulation provided by the foams was adequate but there was a significant added cost to produce these new labels because of a reduction in line speeds (for lamination process) and added shipping costs due to thicker labels. This project was a highly collaborative multi-year project involving the Research and Development and Marketing teams of both companies. Bolger & O’Hearn already had some base knowledge of thin film insulation however; we had very little knowledge of the label substrate (BOPP). Nevertheless, we quickly developed a proof-of-concept coating that provided the confidence for both companies to move ahead with the project.
The final commercialization-ready thin film insulation possessed the following characteristics:
- Initial Dry film thickness of 1 mil.
- Final “foamed” thickness of 25 mils.
- Capable of applying at commercial speeds of up to 1,500 feet/minute.
- FDA, indirect food contact ingredients.
- Ability to ship labels “unfoamed” thereby significantly reducing transportation costs.
Bolger & O’Hearn was paid for all of its involvement in the project and the customer received a portfolio of IP that is test market ready.