Corrugation Powder Africa

Optimizing Adhesive Bond Strength for Corrugated Packaging in East & West Africa with Shalbond’s Gum Powder Solutions

Key Takeaway:

Rapidly expanding corrugated packaging markets in Nigeria, South Africa, Kenya, and Ghana require adhesives that withstand high humidity, variable substrates, and fast line speeds. Shalbond’s Gum Powder formulations deliver instant green strength, robust final bond, and exceptional moisture resistance—empowering production managers to minimize downtime and ensure consistent box performance.

High-Growth Corrugated Packaging Regions in East & West Africa

By 2025 the Africa corrugated packaging market is worth USD 9.03 billion and growing at a 2.28% CAGR, with higher growth in key regional hubs.

• West Africa (Nigeria & Ghana): Nigeria leads with a booming e-commerce sector and FMCG demand. Local corrugated capacity in Ghana is rising due to lower-cost cassava-based adhesives and incentive programs for domestic manufacturing.
• East Africa (Kenya & South Africa): Kenya’s cold-chain logistics and horticulture exports fuel corrugated demand, while South Africa’s large retail and automotive packaging sectors drive a 4.42% CAGR through 2033.

These regions share challenges of high ambient humidity (50–80% RH), variable recycled-fiber substrates, and surging online fulfillment needs.

Persona: Corrugated Box Production Manager

Name: Grace Mwangi

Location: Nairobi, Kenya

Responsibilities: Manage single-facer and double-backer operations, optimize starch adhesive systems, meet daily output targets (60,000+ boxes).

KPIs:

• Downtime ≤0.8%
• Bursting ≥32 ECT
• Adhesive cost reduction ≥5%

Pain Points:

• Glue lap failure under humid conditions
• Viscosity swings causing roller build-up
• Weak green tack leading to misfeeds
• Substrate inconsistency with high recycled content

Needs :

• Gum powders with stable rheology at 50–80% RH
• Rapid gel-time formulations for 200 m/min corrugator speeds
• On-site technical support and training

Real-World Challenges from Industry Discussions

Key adhesive issues noted in African and global forums include:

• Moisture-Induced Bond Loss: Hygroscopic starch adhesives absorb humidity post-drying, causing liner delamination and reduced box compression strength.
• Insufficient Green Strength: Rapid line speeds demand adhesives that set in seconds; conventional starch blends often underperform, leading to web breaks.
• Viscosity Instability: Temperature variations and prolonged tank storage cause shear-thinning or gelation, resulting in either poor pick-up or excessive lift-up.
• Substrate Variability: High recycled-fiber liners resist wet-out, requiring tackifier-enriched formulations to ensure proper fibre penetration and interlaminar bonding.

Shalbond’s Gum Powder Solutions

1. Superior Moisture Resistance

Proprietary starch modifications reduce hygroscopic fillers , limiting moisture uptake to < 0.5% and preventing bond deterioration in 70% RH environments.

2. Rapid Green & High Final Strength

Optimized tackifier and crosslinker ratios deliver green bond strength ≥0.8 N/mm² within 3 s and final tensile strength >5 MPa—enabling reliable first-pass yields at 180–220 m/min corrugator speeds.

3. Consistent Viscosity for Roller Compatibility

Formulated for 30–35 s (Ford Cup #4) viscosity, Shalbond Gum Powders maintain stable rheology over 12 h in-tank, preventing roller deposits and ensuring uniform glue lines.

Patent-Backed Technical Foundations

• EP1897926A1: Describes water-redispersible powder adhesives with finely controlled insoluble polymer fractions, enabling rapid reactivation and strong paper bonds under moisture stress.

Shalbond applies these principles—incorporating redispersible starch and gum chemistries—to achieve proprietary performance in African climates.

Technical Data & Application Guidelines

Mixing & Application:

• Corrugation gum: 10–12% solids; pasting gum: 14–16% solids.
• Reactivation roller: 60–70 °C; adhesive tank: 50–55 °C.
• Use within 12 h of mixing; maintain 50–70% RH in production area.

Conclusion

By leveraging Shalbond’s Gum Powder adhesive solutions—backed by cutting-edge technology—corrugated box production managers like Grace can conquer moisture, substrate, and speed challenges across East and West Africa. The result: reduced downtime, assured box strength, and sustainable cost savings in high-growth regional markets.