top of page
Tantec RGB.png

Case Studies

BottleTEC_3_00006 (1).tif

How Printmasters improved Product Quality and Sustainability

Enhancing Quality and Sustainability with Tantec’s Surface Treatment Solutions


Introduction


Printmasters, the exclusive decorator and value-added services provider for XD
Connects, specializes in delivering over 20 advanced decoration techniques and a
wide range of customization options. With a portfolio of more than 2,500 promotional
products and 300 new additions annually, the company faces the dual challenge of
maintaining exceptional quality while advancing its sustainability goals.
This case study explores how Printmasters partnered with Tantec to implement cutting-
edge plasma and corona surface treatment solutions, achieving significant
operational improvements and environmental benefits.

Printmasters’ Core Business and Expertise


Printmasters plays a central role in the promotional products industry, providing
advanced decoration services including printing, engraving, embroidery, and hot
stamping. Beyond these, they offer variable data printing, individual labeling, and
custom gift set creation to meet diverse client needs.
Their strong focus on quality and customization has positioned them as a key partner to
XD Connects, a leading European supplier of promotional items.

Challenges in Adhesion and Quality


With more than 15 product categories covering a wide variety of materials, finishes,
and substrates, Printmasters faced increasing challenges in ensuring consistent
adhesion for inks, coatings, and labels.


Key issues included:

​

  • Material diversity: Different substrates required tailored surface activation

  • Low-volume runs: Many decorations involved fewer than 500 pieces

  • Efficiency demands: Quick setup and adaptability were essential

  • Quality standards: Ensuring consistent results across thousands of SKUs

  • To maintain their reputation for excellence, Printmasters needed a reliable, flexible, and

        eco-friendly surface treatment solution.


Why Printmasters Chose Tantec

Printmasters’ partnership with Tantec started years earlier, when they acquired a Belgian
company already using Tantec’s corona treatment systems. Over time, their trust in
Tantec grew through industry events, research, and hands-on experience.
Key decision factors:

​

  • Advanced Technology – Tantec’s vacuum plasma systems handled a wide

  • range of substrates

  • Cost-Efficiency – A strong balance between affordability and long-term

  • durability

  • After-Sales Support – Responsive technical assistance and fast service

  • Operational Flexibility – Perfectly suited for short-run, high-mix production


Results and Improvements


1. Enhanced Productivity
By automating the pretreatment process, Printmasters reduced manual labor hours and
minimized downtime.


2. Consistent Adhesion Quality
Across diverse materials, print adhesion and finish quality improved significantly.


3. Optimized Workflow
The new system eliminated production bottlenecks, enabling smoother operations.


4. Safer Workplace
By reducing dependency on hazardous primers and chemicals, operators now enjoy a
safer working environment.

Sustainability Impact


Cosmin Lucean, Innovation & ESG Manager at Printmasters, explains:
“Environmental considerations were a key factor in our decision to invest in Tantec’s
equipment. By significantly reducing the use of chemicals such as primers, we have
achieved a notable decrease in VOC emissions, aligning with our sustainability goals.
This also improves the handling and disposal of hazardous materials, reduces the need for
extensive air filtration, and creates a safer workplace for our operators. Overall, this
investment supports our low-impact policy and strengthens our environmental
objectives.”

With Tantec’s technology, Printmasters successfully achieved:

​

  • Up to 70% fewer VOC emissions

  • Reduced chemical handling and waste

  • Lower operational costs due to less primer and solvent usage


A Trusted Partnership


“We would highly recommend Tantec’s surface treatment machines to other companies,”
adds Cosmin Lucean.
“Their solutions are reliable, their R&D team is impressive, and their overall operations are
exceptionally well-organized. We encourage anyone facing similar challenges to reach out
to Tantec — they likely have the right solution for you.”

Conclusion


By adopting Tantec’s surface treatment technology, Printmasters improved operational
efficiency, print adhesion quality, and environmental performance — all while
maintaining the flexibility required for low-volume, high-mix production.
For manufacturers facing similar challenges, Tantec offers proven, eco-friendly, and
cost-efficient solutions designed to handle diverse materials and complex decoration
needs.

Improving Adhesion on Polypropylene Medical Devices

Improving Adhesion on Polypropylene Medical Devices with Tantec’s VacuTEC 5050


Introduction


For decades, Tantec has been a trusted partner to leading manufacturers, delivering
plasma and corona surface treatment solutions to improve adhesion and ensure
consistent quality.


Recently, one of the world’s leading medical device manufacturers approached Tantec
with a challenge: achieving strong, repeatable adhesive bonding on polypropylene
(PP) surfaces. Polypropylene is widely used in the medical industry, but its low surface
energy makes it extremely difficult to bond adhesives, coatings, or inks effectively.


Tantec’s solution? The VacuTEC 5050, a vacuum plasma treatment system designed to
deliver uniform, reliable surface activation for complex components.

The Challenge: Adhesion on Polypropylene


Polypropylene is a lightweight, durable, and chemically resistant material commonly used
in medical devices. However, it has a non-stick surface that causes:

​

 

  • Poor bonding strength with adhesives and coatings

  • Inconsistent printing and labeling results

  • Higher rejection rates during production

  • ​

The medical device manufacturer had tried primers and other adhesion methods, but
none provided consistent, reliable results. They needed a repeatable process that:

​

 

  • Ensured strong and uniform adhesion

  • Reduced reliance on hazardous chemicals

  • Integrated seamlessly into their existing manufacturing workflow


The Solution: Tantec’s VacuTEC 5050


After in-depth testing and collaborative engineering sessions, Tantec identified the
VacuTEC 5050 vacuum plasma treatment system as the optimal solution.


Key Benefits:

​

  • 360° surface activation – treats the entire device evenly

  • Repeatable and reliable results – ideal for high-quality medical applications

  • Customizable chamber size – standard dimensions 50 x 50 cm; adaptable to

  • customer requirements

  • Easy integration – connects seamlessly into existing production lines

  • Interactive operation – intuitive touchscreen interface for quick setup


How the VacuTEC 5050 Works


The VacuTEC 5050 uses vacuum plasma technology to modify the surface energy of
polypropylene:


1. Vacuum Creation – a pump reduces chamber pressure, removing most of the air.
2. Gas Ionization – a controlled electrical field ionizes the remaining process gas,
creating plasma.
3. Surface Activation – excited plasma particles form polar functional groups on
the device surface, enabling strong adhesion.


For most applications, compressed air is sufficient, but the system also supports special
process gases and custom gas mixtures for advanced treatments.

Results and Improvements


Since implementing the VacuTEC 5050, the medical device manufacturer achieved:

​

 

  • Consistent adhesion on polypropylene components

  • Improved process reliability and standardized quality

  • Reduced chemical usage and safer working conditions

  • Optimized production workflows with less downtime


The VacuTEC has become an integral part of their manufacturing process, ensuring high
performance and regulatory compliance in medical device production.

Technical Highlights of VacuTEC 5050

​

 

  • Chamber size: 500 x 500 mm (customizable)

  • Surface energy improvement: tailored to material requirements

  • Power input: 240V single-phase, 13A

  • Process gases: compressed air or custom gas mixtures

  • Control interface: fully interactive touchscreen

  • Setup time: ready for operation within minutes


Why Vacuum Plasma for Medical Devices?


Vacuum plasma is ideal for precision-demanding applications like medical devices:

​

 

  • Provides uniform treatment even on complex geometries

  • Avoids damaging sensitive materials

  • Eliminates the need for harsh primers and solvents

  • Delivers reliable adhesion results for stringent ISO and FDA requirements


A Proven Partner for Surface Treatment Challenges


Tantec engineers worked closely with the manufacturer to define optimal treatment
parameters and integrate the VacuTEC 5050 into their process.
If your company faces adhesion challenges with polypropylene or other low-surface-
energy materials, Tantec offers tested and proven solutions.

Enhancing Adhesion on PU Catheters

Enhancing Adhesion on PU Catheters with Tantec’s VacuTEC Vacuum Plasma System


Introduction


A leading medical device manufacturer specializing in catheters made of polyurethane
(PU) needed a reliable surface treatment solution to ensure proper adhesion of their
patented hydrophilic coating. This coating is designed to make catheter insertion into
the bladder easier and more comfortable, but it requires strong, consistent bonding to
the catheter surface.


To address this challenge, Tantec partnered with the customer to develop a customized
VacuTEC vacuum plasma treatment system. This solution is primarily used to prepare
the surface of catheter tubing before coating, ensuring optimal adhesion and long-term
reliability.

Why PU Catheters Require Surface Treatment


Polyurethane (PU) is widely used in the medical industry due to its:

​

 

  • Biocompatibility

  • Flexibility

  • Durability

  • Easy sterilization


It’s commonly found in catheter tubing, cosmetic implants, and storage devices.
However, PU has an inherently low surface energy and an open surface structure,
which make it difficult for inks, coatings, and adhesives to adhere properly. Without
pretreatment, coatings may fail, reducing both product performance and patient safety.

The Role of Vacuum Plasma Treatment


Vacuum plasma treatment is a proven and widely adopted technique used to modify
surface properties and improve adhesion performance. While traditionally used in the
electronics industry, its role in the medical device sector has grown significantly for:

​

 

  • Surface cleaning

  • Surface activation

  • Engineering the bonding properties of plastics, rubbers, and natural fibres


By exposing catheter surfaces to vacuum plasma, the surface energy is increased
dramatically. For this particular application:

​

 

  • Before treatment: ~38 mN/m

  • After treatment: up to 72 mN/m


This nearly doubles the surface energy, making it possible for the patented coating to
wet the surface uniformly and bond securely.

How Vacuum Plasma Enhances Bonding


Vacuum plasma treatment chemically modifies the surface by introducing polar
functional groups. This creates a stronger chemical bond between the catheter and the
applied coating — far more robust than a simple mechanical bond.


Key benefits include:

 

  • Improved adhesion strength

  • Increased product reliability

  • Enhanced patient safety


Controlled, Low-Temperature Process


The VacuTEC system operates between 40°C and 120°C, making it a safe, low-
temperature process that avoids thermal damage. Under vacuum conditions, plasma
particles achieve higher kinetic energy and remain active longer, allowing for:

​

 

  • Efficient surface activation

  • Non-thermal chemical reactions

  • Surface modifications not possible at atmospheric pressure


These properties open up new opportunities for treating sensitive materials like PU used
in medical devices.

VacuTEC: For Batch and Inline Production


For this specific customer, Tantec designed a custom VacuTEC system for batch
processing of catheter tubing. However, the same technology can be fully integrated into
inline production for higher throughput environments.

The Treatment Process Step by Step


1. Loading – Catheter tubing is mounted onto the fixture.
2. Activation – The fixture enters the VacuTEC chamber, and the door closes
automatically.
3. Vacuum Creation – Air is evacuated from the chamber via a vacuum valve.
4. Plasma Discharge – Plasma is activated and applied for 30 seconds.
5. Repressurization – Air flows back into the chamber, the door opens, and the
fixture is released.
6. Coating Application – The patented coating must be applied immediately after
treatment for optimal adhesion.
Total cycle time: ~120 seconds per batch.

Results and Benefits


By implementing Tantec’s VacuTEC solution, the medical device manufacturer achieved:

​

 

  • Reliable coating adhesion on PU catheters

  • Improved production efficiency

  • Consistent product quality

  • Enhanced patient comfort and safety

  • Reduced need for chemical primers and associated costs

bottom of page