Innovative Troubleshooting Techniques and Inks / Substrate Reformulation for Decorative Films in Wallcovering Applications
Hi, I’m Steve McEntee, Director of Sales – Inks and Coatings at Penn Color. One of the most rewarding parts of my role is helping customers solve unexpected challenges that affect both their products and their reputation. One case that stands out involved a customer in the wallcovering industry who was using our inks to print décor on PVC films, used for wallcovering in hotels, casinos, and healthcare facilities.
The customer was sourcing PVC films from multiple suppliers, and over time, they began receiving complaints from hotel owners about fading color. The issue became particularly noticeable when furniture and pictures on the wall were moved, revealing stark contrast in color where the wall had been exposed to light versus where it had been covered. The discoloration was reported in some cases after only one year of installation, far short of the typical 10- to 15-year lifespan guaranteed for these types of products.
To get to the bottom of it, we designed a comprehensive testing protocol that simulated real-world conditions. In our labs and in parallel at our customer’s facility, we combined exposure to Xenon arc and LED light to screen various pigment and film combinations. Through this process, we discovered that a specific blue pigment in our ink formulation was interacting negatively with one of the customer’s PVC films under UV exposure. The result was a bleaching effect that dramatically accelerated color fading.
Once we identified the root cause, we moved quickly to find a solution. We tested several alternative pigments and ultimately identified a more robust, chlorine-resistant PCN Blue. This new pigment was selected for its durability and for its ability to be a seamless drop-in replacement with no changes required to the customer’s printing process, and no impact on the aesthetics of their design. Most critically, we took a system approach. At the same time, we worked on the selection of new pigments, we also guided the customer in working with their film supplier to adjust the film formulation for added stability.
From the moment this issue was brought to our attention to the successful reformulation of both the ink and the film, the entire process took just four months. Today, that customer’s wallcoverings are once again meeting expectations - and the hotel walls are looking better than ever!
