Total Cost of Corona Ownership
- Published: August 5, 2026, By Trevor
By Kevin McKell, Chief Sales Officer at Vetaphone A/S
Like most investments in production equipment, it is essential to calculate the TCO (Total Cost of Ownership), because the purchase price is only a part of the overall cost, and this is a trap that many converters and extruders fall into. They look only at the bottom line of the quote to see how much it’s going to cost to buy and completely forget to factor in the on-costs that occur with any machine or item of technology. This applies as much to surface treatment technology as any other element in the production line, so TCCO (Total Cost of Corona Ownership) is a valid acronym.
The calculation needs to begin with the installation. It’s no good buying the cheapest equipment if you or someone else needs to spend time and money assembling and installing it once it arrives. That’s why it’s important to look for a turn-key installation, where all parts are completely pre-assembled and pre-wired so that it’s easy and quick to integrate into the production line with minimal disruption and cost. Then, all that’s required is to install an air/ozone outlet and ensure there is an electrical connection.
Vetaphone’s new VE2C-K model was launched at the recent Plast 2026 expo in Milan and has been specially developed for extrusion applications. It offers a new low in TCCO for extruders looking for high-quality corona technology. Image courtesy of Vetaphone.
The next factor to consider is working-life expectancy. Bearing in mind how harsh some working environments are, it’s essential that the corona equipment is built from the best materials for continuous production in any working environment. Crucially, all parts must be ozone resistant, so choose a manufacturer that has global experience of production environments and climates from well below freezing to hot and humid. What’s needed is the quality that guarantees 24-hour production and a long working life.
Poor quality components and poor build quality cause major problems in any production line – it’s not just an issue with surface treatment. But you don’t want your corona unit to be the weak link in the chain. Cheaper units break down causing a loss of production and they don’t last as long, which will mean further investment and more disruption when a replacement is installed and commissioned.
A major concern for all manufacturers is downtime, because it’s expensive and disruptive. One of the reasons for lost production is non-uniform surface treatment across the width and along the full length of the web. This is countered by a corona system that has automatic power density management, which allows the generator to raise or lower the power setting according to the line speed. This ensures the same treatment is applied per square foot/metre throughout the run. An additional bonus is that the generator automatically starts and stops with the production line and ‘flags’ situations that are outside its capability.
One of the key factors in today’s competitive production environment is seamless integration of all ancillary processes. This includes surface treatment where you need the operator to be able to make adjustments, read data and see any ‘flagged’ issue. A good control panel makes the technology easy to understand and intuitive to use. It collates and utilises feedback from those using the technology in a commercial environment on an everyday basis.
All technology has downtime; it’s a fact of life. To assure high production security, a modular design and construction is preferable for reducing downtime related to maintenance, repair, or upgrade. This applies to the generator module and the corona treater station, where an electrode system in a removable pull-out/push-in quick change cartridge makes for easy maintenance and cleaning. This also offers minimum downtime and increases productivity.
One crucial thing to remember is the importance of using original spare parts, not cheaper copies. This ensures sustained performance and a longer working life. It’s important to ensure that the manufacturer you choose documents all its equipment well, so that wear parts and easy to identify and order.
Keeping ongoing costs down, especially in an era of rising energy rates and the ever-present environmental issues are key considerations. Maximum performance with minimum impact should be your mantra, so choose a manufacturer whose generators use a resonance circuit. This will ensure maximum energy reaches the electrodes and less is lost in heat and will give you more dyne/kW.
So, when the time comes to evaluate your next investment in surface treatment technology, make sure you consider more than just the price on the quote because that won’t even begin to tell the whole story. If purchase price is the only consideration, your corona treater will be the weakest link in your production chain. That’s why understanding the TCCO is so important!
About the Author
Chief Sales Officer (CSO) at Vetaphone AS, the pioneers of surface treatment technology and inventors of the corona process, Kevin is a well-known and highly respected figure in the industry where his knowledge and expertise have improved the performance of printing presses, laminators, coaters and other converting machinery that process filmic and other materials where surface adhesion poses a problem.
A mechanical engineer by training, with first-hand experience in design and manufacturing, Kevin lists a number of blue-chip companies in his work portfolio and has expanded his skills to include health and safety, man management, team building, and his current role in international sales, where he is skilled at pioneering new markets and establishing and building effective sales channels.
One of life’s great communicators, with a good understanding of differing business cultures, he has the ability to relate well to people at all levels of industry and from varying backgrounds. For more information, visit: https://www.vetaphone.com/