For the first time, there is an anti-microbial protected, hard coated film substrate proven to eliminate various bacteria which, if not controlled, could spread to other surfaces and individuals
As the issue of bacterial contamination becomes increasingly critical, manufacturers are responding with the development of a new generation of innovative anti-microbial products.
Here Emma Scowen, industrial product manager at MacDermid Autotype, examines how one such product, a ground-breaking anti-microbial film substrate, is playing a key role in the battle against harmful bacteria.
It is estimated, in recent reports from the National Audit Office, that infections caused by bacteria are costing the UK economy more than £1.4 billion every year, with the cost of treatment and lost productivity being far higher at over £120 billion.
Above and beyond this significant impact on the UK economy, the issue of bacterial contamination is also causing great public anxiety, with 82% of people in the UK being concerned about bacteria in hospitals for instance.
Within many hygiene critical environments, such as convalescent homes, supermarkets, prisons, hospitals and schools, everyday objects and surfaces can harbour and spread dangerous bacteria.
Furthermore, research has proven that hand contact with contaminated surfaces can rapidly transfer bacteria to other surfaces and thus from person to person.
Until recently, however, with the exception of general hygiene procedures such as frequent hand washing and cleaning, there has been limited means of protecting exposed surfaces on keyboards, displays, worktops and doors from contamination.
Hygiene is of growing concern, among health professionals and consumers, and increasingly within industry, as product designers and manufacturing engineers seek to find ways of enhancing the safety and performance of the products and systems that are sold into a wide variety of end-user applications, ranging from medical equipment to restaurant furniture.
One area of recent product development has been the plastics and film substrates used both in the production of membrane keypads and graphics displays, and for the protective layers on exposed surfaces.
In particular, work carried out jointly by MacDermid Autotype, a developer and manufacturer of high performance films and chemicals, and Microban International, a global company dedicated to enhancing high quality consumer, industrial and medical products with built-in protection from microbes, has led to the introduction of an innovative anti-microbial substrate.
Called Autotex AM with Microban, this unique, hard coated polyester film substrate incorporates built-in Microban anti-microbial protection, making it the first material of its type to inhibit the growth of potentially harmful bacteria, mould and mildew.
The film substrate has been developed and designed specifically for the graphics overlay film on any surface application.
This includes membrane keypads, fascia panels, wall coverings, shelf and bench tops, where durability and anti-microbial protection are necessary.
The film's clarity and receptivity to a large number of graphic inks, makes it suitable for a great number of applications.
For example, temporary signs, door panels, patients' bedside entertainment and communication centres and basic instrument panels can all be built using Autotex AM.
The new film consists of a thin base polyester layer, to which a flexible and robust textured coating is chemically bonded.
The coating has a unique formulation, giving it excellent mechanical and physical properties.
The Microban antimicrobial technology is incorporated into the textured coating during the manufacturing process, ensuring an even distribution of the antimicrobial agent throughout the texture and film surface.
The Microban additive works by interfering with the cell wall of micro-organisms that come into contact with the surface of the film, disrupting key cell functions and thereby killing the microbes.
By continuously fighting the growth of harmful bacteria this anti-microbial technology can help prevent cross contamination.
Essentially, Microban protection makes the film more hygienic and provides dependable and constant protection against bacterial contamination in the intervals between cleaning procedures.
This new generation of film substrates has been developed to offer major benefits to manufacturers and end users alike.
The film substrate has an extremely long flex life, making it ideal for tactile membrane keys or curved surfaces; it can easily be embossed without creating stress fractures or weak points; and it offers a consistent low gloss, textured surface with high levels of light transmission.
In addition, it is scratch and chemical resistant, and can withstand the rigours of everyday use.
In order to prove the efficiency as well as to ensure that customers and end users are confident in the long term antimicrobial performance of the new Autotex AM with Microban substrate, extensive testing has been carried out by a leading independent testing laboratory.
Using standard test protocols, variety of different samples, including unprocessed film that was taken straight from the production line, were subjected to simulated graphics printing including jet dryer passes, fusion UV passes and passes under IR lamps.
In addition the film samples were stretched by 20%, to simulate the process of embossing.
Further samples underwent testing to simulate extreme surface wear; this included the texture peaks being removed using sand paper and the surface polished using wire wool until it was smooth.
Finally, samples underwent a test protocol that simulated real life cleaning regimes representing a period of 15 years usage.
The test results highlighted the mechanical and physical properties of the new film substrate and, most importantly, showed that the material achieved a durable biocidal kill result for a wide range of bacteria, fungi and moulds including methicillin resistant staphylococcus aureus (MRSA), salmonella enteritidis, escherichia coli (E coli) and listeria monocytogenes.
It is important to note that although the use of this new generation of films will not eliminate the need for general cleanliness and hygiene, they nevertheless represent a significant step forward in hygiene critical applications and provide a proven and continual protection against the risk of bacterial contamination.
For the first time ever, there is an anti-microbial protected, hard coated film substrate that is proven to eliminate various bacteria which, if not controlled, could easily spread to other surfaces and individuals.
Extensive media attention and the growing instances of infections caused by the spread of bacteria mean that the issues of hygiene and bacterial contamination are of growing concern to consumers and, increasingly, within industry as designers and engineers search for ways to deal with the problem.
The introduction of this latest generation of anti-microbial film substrates represents a new method of combating the spread of infection while retaining the handling, processing and end-use features normally associated with hardcoated polyester films, giving product manufacturers and consumers alike a potentially exciting and cost effective solution.
What is a microbe?.
Microbes or micro organisms are living cells that are too small to detect with the naked eye until they have multiplied to the level of hundreds of thousands.
Under the right conditions, microbes can double in number every 15-20 minutes.
There are several types of micro organisms.
Bacteria.
These are single-celled microbes that reproduce by splitting in two.
Each individual bacterium is capable of carrying out all of the activities needed to metabolise and reproduce.
There are more than 5000 known species of bacteria, with new ones regularly being discovered.
Familiar species of bacteria include E coli and salmonella.
In the right conditions of warmth, acidity and moisture bacteria can multiply extremely fast, producing millions of cells in a few hours.
It is impossible to avoid the presence of bacteria and in fact, many of the bacteria we encounter are beneficial to the environment and even to the human body, aiding the digestion of food for example.
However, some bacteria are harmful and can cause illness.
Fungus.
Fungal cells have an elaborate arrangement of internal membranes.
It is estimated that today over 1.5 million species of fungi exist, being divided into two broad groups: filamentous fungi (including moulds and mushrooms) and yeasts.
Fungi begin life as microscopic airborne spores that germinate on contact with the surface of non-living organic matter where moisture is present.
Mould is then able to penetrate the organic material, secreting enzymes and absorbing water and the digested sugars and starches from the nutrient source.
Mould spores are present everywhere in the indoor and outdoor environment and many of the products found in homes and buildings provide rich nutrient sources.
Algae.
Simple, plant-like micro organisms, algae are often classified at the phylum level according to their colour, ie green, red, golden-brown and brown.
Algae vary in size from microscopic algae to the largest forms such as seaweeds.
While they can vary in habitat, most algae are found in fresh water or seawater.
Algae use the energy of sunlight through the process of photosynthesis to make their own food.
Algae produce more oxygen than all plants combined and play an invaluable role in the ecosystem.
Humans have also found other uses for algae, as food for people and animals, as thickening agents in ice cream, in shampoos and even in some drugs.
In some cases, they can however damage product surfaces for instance a swimming pool filter, the hull of a boat or the exterior of a building.
