Our Process
The Flexlink Zero-Disruption Protocol
Every new partnership starts the same way: with your line, your QA team, and your schedule protected. Our Zero-Disruption Protocol takes you from your current material to a fully qualified, stocked substrate in four controlled stages. You decide when to move to the next one.
Step 1: In-House Spec Audit
Typical timing: 1–2 business days from receipt of your material
No line downtime required. Send us a sample of your current material along with your operating constraints. Our lab analyzes basis weight, caliper, tensile strength, barrier properties, and chemistry, then matches or optimizes the spec before anything touches your floor.
- What you send: A material sample or spec sheet, your application and line conditions, and any current pain points (scrap, contamination, breaks, surface defects)
- What you get: A spec comparison and a recommended material
Step 2: Sample Sheets & Regulatory Documentation
Typical timing: 2–4 business days from receipt of request.
We ship physical sample sheets along with the complete technical documentation your QA team needs to sign off upfront, including Certificates of Analysis (COA), FDA compliance statements where applicable, and safety certifications. No chasing paperwork after the fact.
Step 3: Controlled Single-Roll Trials
Typical timing: Usually 4–6 weeks from trial approval, depending on product line and dimensions
We slit custom trial rolls to your exact core size, outer diameter, and tension specs. Trials are designed to run during a standard maintenance window or shift change, not in the middle of a production run. One roll, on your line, in your real conditions, before you commit to volume.
Step 4: Traceable Supply & Buffer Stock
Typical timing: 12–14 weeks from your initial commercial order
Every roll traces back to its parent (master) roll lot data, so any quality question has a fast answer. During cutover, we hold dedicated buffer stock at our onshore distribution hub to protect you against supply interruptions while your new material ramps up.
Step 5 (recommended): Scheduled Releases & Ongoing Support
Typical timing: Ongoing
Once you’re qualified, we keep inventory working on your schedule with release programs built around your forecast. And when your process, product, or specs change, the same technical team that qualified your material is a phone call away.
Timeline at a Glance
| Stage | Clock Starts | Typical Timing |
|---|---|---|
| 1. Spec Audit | Receipt of your material | 1-2 business days |
| 2. Samples & Documentation | [Confirm trigger] | 2-4 business days |
| 3. Single-Roll Trial | Trial approval | 4-6 weeks (varies by product and dimensions) |
| 4. Traceable Supply & Buffer Stock | Initial commercial order | 12-14 weeks |
| 5. Scheduled Releases & Support | Qualification | Ongoing |
The Result
You get a fully qualified, high-runnability substrate that reduces line scrap and lowers your landed cost, without burning engineering hours, risking unplanned downtime, or committing to massive mill minimums.
Frequently Asked Questions
What do you need from me to get started?
A sample or spec sheet of your current material, plus your application and line conditions. If you don’t have a spec sheet, a physical sample is enough for our lab to start.
Do I have to shut down my line to test a new material?
No. The spec audit happens in our lab, and trial rolls are built to run during a maintenance window or shift change.
What documentation will my QA team receive?
Certificates of Analysis (COA), safety certifications, and FDA compliance statements for food-contact grades, delivered with your samples.
How long does it take to switch materials?
Most lab work and sampling is done within about a week. Trials typically run 4–6 weeks from approval, and buffer stock is in place 12–14 weeks after your first commercial order.
Do you have minimum order quantities?
Commercial orders typically start at one pallet, depending on the product. For coffee and tea grades, that’s roughly 500 lbs., a fraction of what most mills require. Trials are smaller still:
- Coffee and tea: a single roll, typically 1,000 linear meters.
- Steel and glass interleaving: one counter roll in standard widths (36″, 48″, 60″, or 72″), or one master roll for custom dimensions.
- Flame-retardant, tag and label, and lumber wrap: a single sample roll in standard dimensions. Custom dimensions are scoped case by case.
Can you match the material I’m using now?
In most cases, yes. Our lab matches your current spec or recommends an optimized alternative that improves runnability or lowers cost.
