Contract Manufacturing

Our Service: from product development to 24/7 production in three steps

The best ideas are developed in collaboration with strong partners. The Koehler Paper Group works with customers and suppliers in all areas of business on the basis of this principle. This type of partnership is particularly crucial when it comes to microencapsulation contract manufacturing, since every project begins with a product idea that needs to be turned into reality. With almost 50 years of expertise in the development and production of microcapsules for carbonless paper, the newly founded Koehler Innovative Solutions is expanding this position, particularly to meet the requirements of its customers for industrial applications. The goal is the large-scale production of customized requirement profiles using various microencapsulation Technologies.


Product development

The first step in the development of a suitable microcapsule is the exact description of the applications and the resulting requirements with regard to the capsule properties. The release, size of the capsule, and specific properties of the core substance are only a few parameters that affect both the formulation and process development.

Laboratory scale

Laboratory scale

The suitability of the chemical agent for microencapsulation is assessed in initial feasibility tests. Subsequently the active substance is encapsulated in laboratory scale providing samples for application testing. If an existing capsule system can be used, the compatibility of the core and wall materials is scrutinized, which is generally a productive project. More development work is necessary if the goal is a customized capsule with new functionalities and wall materials.  This requires however, a partnership agreement with defined development stages and milestones.

Samples for application tests are produced at a laboratory scale of 0.5 kg to 1 kg.

 

Pilot scale and scale-up

Pilot scale trials

Writing the formulas and process scale-up are followed by pilot production batches in our pilot plant. The long experience of our employees in performing laboratory and pilot tests ensures fast process adjustments enabling an easier transfer to the next larger installations. In this test phase many options for possible process optimization are automatically incorporated. The sample quantities produced in the pilot plant range from 100 kg to 300 kg per batch in order to be used for larger applications or market trials.

 

Production

Production
 
 

Koehler operates production facilities of various sizes for manufacturing microcapsules. We produce mid-sized production quantities in batch sizes of 1.8 to 3.6 tons and an annual output of approximately 2,000 tons. Up to 13,500 tons of capsule dispersion can be produced for large-volume products. This makes Koehler one of the world’s largest suppliers in the encapsulation business. These capacities allow us to react with flexibility to our customers’ requests.

Our goal is to continue making advances in the field of microencapsulation in the coming years, to expand the range of products and services we can offer to our customers, and to open up new areas of business. In this context, we are equally focused on the development of alternative encapsulation systems for innovative applications as on sustainability, environmental protection, and occupational safety.

 

Quality control

Quality control

Delivering products on time and the consistent quality of the microcapsules are our top priority. At our quality assurance laboratory, we conduct a wide array of customized analyses.
The standard physical specification parameters defined include total solids content, viscosity and capsule size distribution. The latter is determined via laser diffraction. The capsules can also be evaluated visually on scanning-electron-microscope images. For chemical analyses, wet-chemical as well as various spectroscopic and chromatographic methods are available.

 

Contact

Papierfabrik August Koehler SE
Business Unit
Koehler Innovative Solutions
Hauptstrasse 2
77704 Oberkirch
Germany

+49 7802 81-0

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© 2016 Koehler Innovative Solutions