Latestreviewofcoatingmethods2oct2016 161002052626

We Promise to attend your Technical need
03 Sept
2016
[ Introduction
Coating Process Technology is in widespread
use. Coating is necessary for modification, or
improvement of the substrate to make it more [ Coating
suitable.
Several Industries are based on coating Methods]
process technology. Adhesive coating ,
Printing, Flexible laminates are the few
examples.]
Latest Review
of Coating Methods
for Adhesives , Oct 2016
By Shrikant Athavale
Prathith Consultants
Pune India.
Email : psatechno@gmail.com
Coating Methods
Coating Process Technology is in widespread use.

Coating is necessary for modification, or improvement of the
substrate to make it more suitable.
Several Industries are based on coating process technology.
Adhesive coating , Printing, Flexible laminates are the few
examples.
The basic steps in continuous production of coated substrates are
as follows.
1. Preparing the coating solution
2. Unwinding the substrate roll
3. transporting / passing it through the coater
4. applying the coating from the coating solution
5. drying the coating
6. winding the final coated roll
7. Converting the coated substrate to final size
Coating Methods
There are few other operations that are often used , such as,
a) surface treatment on the substrate to improve adhesion.
b) cleaning the substrate prior to coating , to reduce contamination
c) lamination with other substrate
Different types of coatings methods are used depending upon

the substrate as well as the end product requirement.
These coating machines are available in various sizes , from
pilot coaters using narrow webs , 150-600 mm wide and running
at low speeds , 5-10 mtrs / min , to production scale machines
using wide web's , over 1500 mm wide and coating at 50-200
mtrs / min. A typical coating machine is shown below.
Coating Process
The application of a liquid to the traveling web / substrate is

accomplished by one of the many coating methods. Widely used
coating methods are Reverse Roll, wire wound or mayer rod/bar,
direct and offset gravure , slot die, blade, knife over roll , air
knife , comma etc.
The choice of the method depends on the nature of the web/
substrate , the rheology of the coating fluid , the solvent the wet
coating weight desired, the desired coating width and speed, the
no of layers or coating to be applied simultaneously , cost
considerations, environmental considerations .
Coating Process
The coating method should be chosen based on the specific

requirement. many a times a method is selected based on the
availability of a specific coating applicator.
even though it may not be the best choice. much time , money
and raw materials may be wasted by trying to make the product
by a process that is not suitable.
The coating method may be too narrow at the conditions selected
or it may be impossible even to obtain a quality coating.
A process that works well at low speed in laboratory or pilot
coater may not be appropriate for a manufacturing plant , coating
at high speeds . Similarly a high speed coating plant may not be
appropriate for laboratory trials.
Coating is a very Important
process involved in the Manufacture
of Adhesive Coated Products
The selection of the best roll coating method for any
particular type of work depends on a number of
factors. The key factors that need to be considered are
as follows:
1. Type of adhesive
2. Thickness of adhesive coating
3. Thickness of substrate
4. Width of substrate
5. Full coat or partial coat
6. Handling after coating
7. Cleanup
There are Various Coating Methods available
Gravure Coating
Metering Rod / Myer Bar Coating
Knife over roll coating
Comma Coating
Reverse Roll Coating
Hot Melt Coating / Extrusion coating
Slot Orifice coating
Calendaring
Immersion / Dip coating
Curtain Coating
The Coating Methods can be classified by the principles used to
control the coating weight.
There are three basic types:
• Self-Metered : Here in the coating equipment controls the

final coverage. Examples are Comma roll, reverse roll, dip
• Doctored : Here in the applied coating is metered lateron or

applicator device removes the excess applied coating fluid to
control the final coverage. Examples are air knife, Mayer rod and
blade & knife coaters
• Pre-metered : Here in all fluid fed to applicator transfers to

web. The volume of solution supplied to the applicator controls
the final coverage. Examples are slot die, gravure and curtain.
Considerations in selecting a coating method
Selecting an appropriate coating method is a challenge because

there are currently many applicators in routine use and each of
these has unique capabilities in terms of the coating solution
variables that they can apply and the resulting coated substrate
properties. Interestingly all of the methods that have been
developed since the first roll coater in 1850 are still in routine use
The attached table summarizes the ~ 40 major coating method
categories by the principle sued to control the wet coating weight,
self metered coating, doctored coating and pre-metered
coating. Each of these methods has several possible
configurations so that there is large number of method to choose
from.
Continued
The typical approach to selecting the coating method for a new

product or an upgraded old product is to establish the product
requirement, coverage level and uniformity, number of layers,
physical quality, volume, substrate, drying conditions, and
solutions properties. The requirements are the compared with
method capabilities and best method selected.
However, there are some additional criteria that are often ignored
and should be considered when selecting a method. The coat
ability window is an operating diagram which indicated the stable
process regions in which the product can be coated with no
defects. It combines the effects of line speed, coating weight,
applicator variables to determine this region. When determined
this will indicate if there is a viable operating region. The basic
values in available tables do not show this.
Continued
The cost and technical effort to install and develop the coating
applicator should be considered. The older established method,
gravure reverse roll, Mayer Rod are inexpensive and can easily
be installed with the availability of cartridge. There is also a large
technical base for these methods and they can be relatively easy
to operate. Slot die coater is expensive and is technically
sophisticated. Considerably more technical effort is needed
to run this process. Often the simpler method is the best choice.
High line appears attractive but they may not be suitable for all
methods. With low volume products the start-up time and initial
losses until quality is established can adversely affect costs.
Continued
This loss is minimal for a high volume long coating campaigns.

However, it can be significant for a small volume product.
Therefore, for low volume product a lower line speed which is
easy to start and maintain may be preferred.
Doctored Mode Self-metered Pre-metered
Air knife metering mode Comma direct/indirect Curtain Precision

Dip & scrape Dip Extrusion
Dip & Squeeze Direct Roll Flexo
Doctor Blade Direct roll hot melt Gravure direct
Floating knife Reverse Roll Gravure offset
Kiss coater gravure reverse
Knife over roll Hot Melt
Mayer rod Slot Die
Metering Bar
After monitoring the coating methods being industrially
used in order to determine the most widely used web
coating methods.
The results of the most recent survey are as follows:
This information is very useful to select a method most

appropriate
Covered Rollers
A discussion of rollers for the adhesives and sealants sector

would not be complete without a mention of coating rolls.
Regardless of the adhesive application method, some type of
coating roll is usually used to spread and evenly distribute the
adhesive/sealant.
Coating rollers may seem mundane, but their makeup and
design must be finely tuned. Specified tolerances as tight as
“half-a-thou” total indicated run out (TIR) are common. That’s
one-half of one thousandth of an inch; perfect concentricity is a
must. Attribute this exactitude to the familiar need for a very
thin, very even layer of adhesive. If the coating roll is out of
round, adhesive application will be uneven.
Covered Rollers ( Continued )
Coating rolls are virtually always covered (seldom just bare

steel), and the compound choice is fairly important. Many
manufacturers say they have a “rubber-covered roller,” but few
roll covers are actually natural rubber. Nitrile is one of the most
common roll cover compounds for coating rolls. Nitrile wears
well and supports the most common durometer range for
coating rolls: 55-90 durometer (Shore A). The higher the
durometer value, the harder the compound.
Where allowable, some engineers order an extra-thick nitrile
coat (0.75-1.00 in.) and then occasionally order a regrind of the
roll face (using a “kiss grind” to remove the top layer of
gunked-up roll cover, usually just a few hundredths of an inch).
This saves money vs. completely recovering the roller every

time it becomes worn, and it is possible to achieve 2-4 regrinds
out of a thick coat.
Nitrile is also available in an FDA-approved version, which is
required in the food and pharmaceutical industries. For FDA-
critical applications, it is also preferable to have the roller core
fabricated from stainless steel rather than the standard carbon
steel.
Ethylene propylene diene monomer (EPDM) is another popular
coating roll compound. This synthetic rubber features good heat
and chemical resistance, with fairly good release. It can also be
applied thick and reground.
High-release silicone is another popular option for coating rolls,

given its high release and heat resistance traits. It lacks the
durability of EPDM or nitrile, but there is no substitute for the
release offered by silicone. It is used extensively in plastic film
and paper applications. However, in addition to its higher up-
front cost, silicone does not regrind well, so rolls must be
completely recovered when worn.
Coating rollers are usually finished in one of two ways: either
very flat and smooth (“micro polish” finish) or with very tightly
spaced serrations or spirals (16-32 radial serrations per inch).
While every plant employs its own proprietary processes,
chemicals and techniques to optimize performance, making it
difficult to develop hard and fast rules about what works best,
these are very common options.
Additional Considerations
High-tech elastomers and thermal transfer coefficients have
added complexity to roller technology, but they should not be
intimidating. With the right knowledge, you can make them
work wonders for your plant. For plant managers wishing to
increase overall output, one easy method is to increase
web/stock width. This means increasing the width of all rollers,
which is not as difficult as one might think. Existing rollers can
be reverse-engineered, and new rolls can be fabricated with the
old diameter and bearing fittings, but with a wider width. This
is a great way to expand capacity without purchasing entirely
new machines.
The final item all engineers should note is balance. Whether

you’re using coating rolls, wiper rolls or chill rolls, they need to
be balanced for the specific line speed. Rolls should undergo
static and dynamic balancing procedures. Static balancing
eliminates loping (which is what happens when the roller stops
and still wants to roll over due to a heavy spot). Dynamic
balancing eliminates operational vibration. The roller maker
will use special balancing machines to set the roll in full
rotation at the designated speed. Special sensors help detect
areas of imbalance, so technicians can then adjust the weight
distribution to achieve perfect rotational harmony. Unbalanced
rollers result in damage to bearings, wasted stock and poor
processing results.
Don’t underestimate the importance of your plant’s rollers.

They are bound to touch your products at multiple points along
the line—not just at the adhesive application station. Keep your
rollers clean and balanced, and don’t be afraid to renew the
covers. These expenditures will pay you back with reduced
waste, higher line speeds, and better finished products.
About Roll Coaters
- How roll coaters work
- Coating thickness control
- Feedroller configurations
- Selecting a roll coater
How Roll Coaters Work
Roll coating machines are commonly used for the application
of a liquid to the surface of a part. Rollcoaters can be used to
apply liquid adhesives, paints, oils, and coatings such as
varnish or clear finish coats. Rollcoaters can take many
forms, from simple paint rollers to sophisticated coating
machines with multiple rollers. A roll coating machine works
by transferring a layer of coating from the surface of a roller to
the surface of a part. When this happens, a phenomenon know
as “film splitting” occurs. The layer of coating on the surface
of the roll splits – part of it stays on the roller, and part sticks
to the surface of the part. The percentage of coating that sticks
to the part (the substrate) depends on the surface
Characteristics Of Both The Roller And The Substrate.
Coating Thickness Control
With most rollcoaters, there is some means of controlling the
thickness of the coating on the surface of the roller before it
contacts the substrate. The three most common approaches to
controlling the coating thickness are metering blade, metering
roller, and transfer from another
roll.
Metering Blade
A typical arrangement for a metering blade is shown in Figure
#1. Coating is picked up from a reservoir by the application
roller. As the coating clings to the roller and is carried up by
the rotation of the roller, only a certain amount can pass
through the gap between the metering blade and the roll
surface. The excess flows back to the tank. Metering blades
are usually made with some means of adjustment, so coating
thickness changes are made by moving the blade to open or
close the gap.
In some cases the metering blade may be moved forward and
back on its mount plate, It can also be rotated to change the
gap between the metering blade and the roller. The
advantages of a metering blade over other means of coating
thickness control are low cost, simplicity of design, and the
fact that the metering blade system does not require much
space. Two disadvantages are the potential for clogging and
potential for roller damage. Clogging can occur if debris or
foreign matter in the liquid gets caught in the gap between the
coating roller and the metering blade. This can block a
portion of the coating from passing through the gap, which
can cause streaks or inconsistent coating results. In cases
where the debris is abrasive, it can cause damage to the
surface of the roller. Some types of coatings also tend to
congeal or clump if subjected to situations where there are
shear forces on the liquid. This situation occurs between a
metering blade and a coating roller.
In some cases the metering blade may be moved forward and
back on its mount plate, It can also be rotated to change the
gap between the metering blade and the roller. The
advantages of a metering blade over other means of coating
thickness control are low cost, simplicity of design, and the
fact that the metering blade system does not require much
space. Two disadvantages are the potential for clogging and
potential for roller damage. Clogging can occur if debris or
foreign matter in the liquid gets caught in the gap between the
coating roller and the metering blade. This can block a
portion of the coating from passing through the gap, which
can cause streaks or inconsistent coating results. In cases
where the debris is abrasive, it can cause damage to the
surface of the roller. Some types of coatings also tend to
congeal or clump if subjected to situations where there are
shear forces on the liquid. This situation occurs between a
metering blade and a coating roller.
For this reason materials such as latex adhesives do not run
well in machines having metering blades. This type of
adhesive would form clumps which would clog the
metering blade to roller interface.
Metering Rolls
Typical metering roll arrangements are shown in figure #2. In
a metering roll system, the thickness of the coating is
controlled by adjusting the gap between two rollers. In a
typical bottom coating application the coating is picked up
from a reservoir and carried up to a nip point by one roll, then
the excess is metered off by a second roll which also serves as
an application roller. A similar concept is used when coating
must be applied to the top surface of a part. Coating is held in
the valley formed between the metering roller and coating
roller, and the gap between the rollers is adjusted to change the
coating thickness.
Metering roller systems are more expensive to build than
metering blade systems, but have several advantages. They
are more tolerant of debris or foreign matter in the liquid,
since it can often pass through the gap between the rolls and
go back into circulation. If the coating roll and metering roll
are run at similar surface speeds, shear sensitive materials
such as latex can be applied without problems. In some
situations, the coating roll and pickup roll are run at different
surface speeds. This can be done to minimize the formation of
foam in the tank, or to help smooth out the layer of coating on
the coating roller.

In reverse roll coating, the surface of the part is fed across the
coating roller in the opposite direction to the surface travel of
the coating roller. This causes the coating roll to serve both as
an application roller and a wiper roller.
A small puddle of coating can form at the interface of roller
and substrate, and this flows onto the part as it passes under
the coating roll. A reverse roll coating arrangement is shown
in Fig 3.
Reverse roll coating is used to apply heavier coatings than
might be possible with forward roll coating. It is also possible
to apply a very smooth coating by using the reverse roll
technique. Since the coating is heavier, it tends to flow out
better, and the flow from the puddle at the roller to part
interface tends to smooth out the coating. The result of these
two effects working together can provide coatings that are
very flat and smooth.
The difficulties in reverse roll coating are in driving the part
and in dealing with any coating build-up on the leading or
trailing edges of the part. In order to travel in the opposite
direction from the coating roller, the part must be driven in a
positive manner so that it does not slip.
This can be done with pressure rolls having high friction
coverings, with vacuum conveyer systems, or with drive belts
having cogs or raised bosses to push the parts through.
If a very heavy coating is being applied, it can drip over the
lead edge or trailing edge of the part. With some types of
parts this does not pose a problem, but with others it can cause
coating to transfer to the pressure rolls or feed conveyer and
require cleanup. This problem can usually be controlled by
finding the optimum settings for coating weight, roller speed,
and the speed of part travel.
Transfer Rolls
Transfer roll systems (Fig 4) are actually a variation of the
metering roll system, and utilize additional rollers to transfer
the coating from the reservoir to the final point of
application. Because additional rollers are involved, these
systems are more expensive than designs using only a
metering roller and application roller,
but there are several reasons why transfer rollers are used in
some types of equipment. These reasons are coating
thickness, roller space limitations, and special roller surface
material requirements.
In general transfer roll systems are capable of depositing a
thinner coating than two roll systems. This is because a film
split occurs at every roller interface, so the film of coating will
be thinner on each consecutive roller in the roller train.
Roller space limitations also may dictate the use of transfer
rolls. In some types of equipment, there is not enough space
to place large diameter metering rollers close to the
application point, and transfer rolls can be used to carry the
coating from the initial metering point to the application point.
Transfer rolls can also be used in situations where the
application roller must be made of a material that is not well
suited to use as a metering roll (such as a soft rubber).
In these cases, metering of the coating is done with metal rolls
or hard surfaced rolls, and the coating is transferred to the
application roll. This configuration can also be useful in
situations where rolls are used to transfer a pattern, such as
certain types of printing presses. The coating is metered out to
the surface of one roller, and the application roll picks up the
coating on a printing plate wrapped around the application
roll. The plate transfers the coating to the part.
Besides cost, one disadvantage of transfer roll systems is that
they are more difficult to adjust and calibrate than metering
blade or two roll metering systems. In some situations
additional rolls or wiper blades must be added to prevent an
accumulation of coating on rolls when parts are not being
coated.
Post Application Metering
In many applications roll coating machines are used to apply
an adhesive or finish coating to a part,
POST APPLICATION METERING
In many applications roll coating machines are used to apply
an adhesive or finish coating to a part, but the thickness or
finish of the layer being applied does not meet the
requirements of the end product. In these cases a secondary
metering method can be used after the coating is applied to
either thin out the coating, smooth it, or texture it to meet the
final requirements.
Almost all post application-metering situations are used when
the material being coated is in the form of a continuous
web. One method that is very popular is the use of a mayer
rod or mayer bar. This is a rod wound with a layer of round
wire. This device can be used to both meter and smooth out a
layer of coating. The bar is used as a scraper bar to wipe off
excess coating, and the spaces that exist between the round
wires serve to meter out a uniform layer of coating.
In most cases the material being metered off will form a
series of peaks and valleys that will flow out to form a smooth
uniform layer. Mayer bars may be used in sequence to do
rough metering then fine metering/smoothing, and are used on
many production lines that produce pressure sensitive films,
tapes, and other materials that require a thin, smooth finish
coating. A configuration using a mayer rod is shown in FIG 5.
In certain cases, application rolls can be built with surface
textures that provide the type of surface finish desired without
post-application metering. The ability to do this will often
depend on the characteristics of the coating being applied, as
well as the characteristics of the substrate. With the right
combination of characteristics, a simple machine may be able
to produce results that normally would be produced by a more
complex machine. Some machines are built with application
rollers having grooves, knurled surfaces, or engraved surfaces
designed to carry more coating than can be carried by a
smooth roller.
The surface texture can be used as a method of controlling the
amount of coating deposited by a roller.
Web Coating
The majority of coating applications are ones where a
continuous strip (web) of material is coated, then dried (or
chilled), and rewound into a roll. Web coating lends itself to
high production rates, and can be used with almost all types of
adhesives and coatings. Many web coating applications
utilize roll coaters to apply the adhesive or coating, and most
utilize some form of post-application metering. In general,
web coating is done at much higher speeds than sheet coating,
and considerable attention must be given to factors such as
proper web tracking, web tension control, web flutter, and
stretching. Since the web is a continuous strip, it can pass
over a number of rollers as it is being coated or treated, and
some web coating configurations can be very complex.
An engraved roller (gravure roll) is used in many web-coating
applications. This is used to transfer a very precise amount of
adhesive to the web. Two typical web coating configurations
are shown in Fig 6, both of them utilizing a gravure roller.
Pressure Roll Configurations
With any roll coater, the substrate to be coated must be
brought into contact with the application roller to pick up
coating. In some situations the part can be directly pressed
against the coating roller by a pressure roll, and in others the
substrate must be guided over the surface of the coating roller
so that it just kisses the roller with enough contact to pick up
the liquid. Pressure rolls are sometimes called feedrolls,
backup rolls, or guide rolls.
The configuration of the pressure roll relative to the coating
application roll is usually determined by the thickness and
flexibility of the substrate to be coated.
If the pressure roll is too close to the coating roller there is a
possibility that it can pick up excess coating that flows off of
the substrate, and then transfer this coating on the opposite
side of the substrate. In some cases a droplet of coating can
travel around on the surface of the pressure roll. This can
allow it to pick up a bit of coating on each revolution until the
roll becomes almost totally covered, requiring that the
equipment be stopped for cleanup.
When coating thin substrates the pressure rolls must be a
sufficient distance from the coating roller to avoid
contamination, but still ensure that the substrate can be driven
through the machine and pick up a coating. This can be
accomplished by locating the pressure rolls in such a way that
the substrate is forced to bend over the coating roller, or by
pressing the part directly against the coating roller with the
pressure roll and removing any excess that transfers to the
pressure roll with a wiper or cleaning roll.
A third technique is to coat only a portion of the substrate and
leave the edges uncoated to avoid any transfer of coating.
If the substrate to be coated is sufficiently thick there is less
chance of coating transfer and the pressure roll can be located
so that it presses the part directly against the coating roller.
Different configurations of pressure rolls relative to coating
rolls have been used for various types of equipment. Some
typical configurations are shown here: In the configuration
shown in Fig 8 the substrate must flex as it hits the coating
roll, and the deflection creates a slight pressure of the
substrate to the roll. Once the substrate is in contact with the
roll, the surface tension of the adhesive will tend to cause it to
stick to the roll and be pulled through the machine. The
stripper points indicated are small knife like fingers designed
to break the leading edge of a flexible substrate free of the
coating roller and allow the part to feed through without
wrapping around the coating roller.
This type of single pressure roll configuration is typically used
with paper.
With the roll configuration shown in Fig 9 the two pressure
rolls force the part to cup over the coating roller and pick up a
full coating. The part flexes upward as it passes under the first
roller and hits the coating application roll, and is forced
around the coating roller as it hits the second pressure roll.
This roller arrangement can be versatile – it can often be used
with a range of substrate thicknesses, since moving the
pressure rolls relative to the coating roller can allow paper to
be coated when the rolls are close to the coating roll, and
thicker parts coated as the pressure rolls are moved away from
the coating roll. By raising the dual rollers high enough above
the coating roller, it may be possible to also coat rigid and
semi-rigid substrates with this roll configuration. Stripper
fingers are generally used with flexible substrates, but may not
be required with stiffer materials.
In Figure 10 the part is pressed directly against the coating
roll by the pressure roll. If the part has sufficient thickness,
stripper fingers are not needed since the part will not cling to
the coating roll. Pressure rolls may or may not be driven,
depending on the type of material being coated and the type of
adhesive, since some types of adhesive generate sufficient
driving force to pull the part through the machine.
The configuration shown in Fig 11 is designed to force a
travelling strip of material to come in contact with the coating
roller and pick up coating. Web guide rolls do not need to be
driven, since the web is generally pulled by a rewind or take-
up roll, and the tension on the web creates the pressure of the
substrate against the coating roller.
In web coating, it is possible to pull the substrate over the
coating roller at a different speed than the surface of the
roller. This technique is often used to deposit a thinner layer
of coating than would be deposited by the roller running at the
same speed as the web.
The travelling action of the web can also cause the coating
roller to act as a wiper bar, so that the coating is smoothed out
as it gets squeezed between the web and the coating roller.
Selecting A Roll coater
The selection of the best roll coating machine for any
particular type of work depends on a number of factors. The
key questions that need to be considered are as follows:
A. Type of adhesive
B. Thickness of substrate
C. Width of substrate
D. Full coat or partial coat
E. Handling after coating
F. Cleanup
A. Type of adhesive – (or coating)
The type of adhesive or coating will influence the way the
liquids are brought to the metering point. Although most
adhesives will work for short periods of time in any type of
roll coater,
problems can occur with certain adhesives that would cause
the coating results to become inconsistent as the material runs
for longer periods. Some general guidelines are as follows:
1) Evaporation of the solvent or water in an adhesive is a
major consideration in how well it will run in a roll
coater. When running solvent based materials, as little surface
area as possible should be exposed, and material should be in
constant agitation to prevent dead areas which can form a skin
of partially dried adhesive. Machines designed for solvent
base adhesives or fast setting water base adhesives would have
rollers shielded as much as possible, and would include pumps
or other methods to keep the material in constant circulation.
2) Machines for latex-based adhesives would be designed
to minimize areas where the adhesive would be subject to a
shearing action which could cause clumps to form.
3) It should be easy to add fresh adhesive to any machine.
The design of the tank should be a compromise between the
capacity and the exposed surface area. Too large a tank may
cause too much surface area to be exposed to evaporation, but
too small a tank may require constant refilling. Automatic
refill systems can be fitted to some machines to alleviate the
need to refill constantly.
4) Some types of materials do not flow well, and need to
be pumped to the metering point. In some cases these
materials can be carried up by a pickup roll that rotates slowly
enough to be wetted by then adhesive, but in other cases
pumping systems are required. This is especially true with
certain high viscosity materials such as epoxies, solvent
cements and urethane adhesives.
5) Certain types of adhesives and coatings have special
characteristics that must be taken into account when selecting
or designing a roll coater to handle them. An example of this
are Ultraviolet cured coatings (UV cure).
Machines that are used to apply these coatings must have
shielding or guarding in place to keep the coating shielded
from light as much as possible, since light exposure can cause
UV cure coatings to catalyze earlier than desired or can
degrade the characteristics of the coating.
The type of adhesive will affect the choice of materials for the
rollers and reservoir, the approach to coating thickness
control, the method of machine cleanup, and the way that
coating gets delivered to the metering point. Certain types of
adhesives (such as hotmelts, waxes and certain high viscosity
materials) require that the machine or the rollers be heated to
melt the material or lower the viscosity to a point where it can
be applied. Some adhesives or coatings will react with certain
metals or other materials, and this can degrade the adhesive as
the machine runs, or cause damage to the coater. Examples of
this are the reactions of copper containing alloys with latex
cements and U.V. cured adhesives.
Other examples of incompatible materials would be aluminum
components used with highly acidic adhesives (such as hot
animal glue). In this case the metal components would be
attacked and damaged by the glue.
Some adhesives are sensitive to a shearing action which
occurs with a scraper blade, and can tend to congeal when
subjected to this type of force. These adhesives and coatings
must be run in machines having metering rollers.
For adhesives and coatings that must be heated either the
rollers must be heated directly or the tank which holds the
material must be heated, and the heat from the tank and
material transferred to the application roller. The need for
heating can limit the choice of materials for the roller, since
any material selected must be capable of maintaining critical
dimensions when heated to the operating temperature.
With any type of coating machine the type of adhesive or
coating will affect the cleanup method.
Some types of materials can be easily cleaned – others require
extensive washing with solvents or water to remove any
residue. Most machines used for the application of hotmelts
do not require cleanup. The adhesive is simply allowed to
cool and hardens up in the machine. One exception to this are
the “reactive” hotmelts or “moisture cure” hotmelts which
must be purged from the equipment before it is shut down.
B. Thickness of substrate
The thickness of the substrate determines the type of feed roll
configuration that will give the best results in coating the
part. The part must be able to come into full contact with the
coating roller to pick up a consistent coating, but should not
cause the coating to transfer to the feed roller (or feed rolls).
Thin flexible substrates (such as paper), are usually best
coated by using an offset pressure roller or dual feed roller
arrangement, and coating of individual sheets will require the
use of stripper fingers.
Extremely flexible substrates such as fabrics, thin foam, non-
woven fabric, thin rubber etc, can be very difficult to coat
since they will tend to bunch up and fold over themselves as
they exit the coating point. In some cases, these types of
material can only be coated using a backing board of sufficient
stiffness, coating them in a web form, or by leaving a portion
at the leading edge uncoated, and using this part to pull the
substrate through the coating point. This can be done by
loading the part into the coating machine with the feed roller
open, then bringing the feed roller into a position where it can
drive the part while there is some tension on the part to keep it
from going slack and bunching up.
Thicker or stiffer substrates can be driven with a dual feedroll
or single feed roll arrangement. In some cases, stiff substrates
such as plywood or fiber board can present problems, since
they may have high and low spots that will bridge over the
coating roll and create voids in the coating.
For these types of materials a soft faced coating roller may be
needed to contact the entire surface and apply coating.
CWidth of Substrate
In general, the width of a roll coating machine should be at
least 2 inches wider than the widest part to be coated. With
this extra width, if the part is loaded into the machine slightly
crooked, the full surface will still get coated.
D. Full coat or partial coat
Roll coating machines are available that can apply coating to
only a portion of a sheet or the full surface. There are also
pattern coaters available that can apply stripes or other types
of patterns in the same manner as a printing press (see transfer
roll systems). In selecting a coating machine, it is important
to define the area to be coated. Is it full surface, a pattern, or a
stripe along one edge?
E. Handling after coating
Once a part is coated with adhesive, it can become much more
difficult to handle than a dry part, so it is important to think
about how the part will be handled once it is coated.
The simplest and least inexpensive roll coaters coat the bottom
surface of the part. This means that the part must be handled
immediately as it exits the machine, and must be handled by
the coated surface. With many types of parts this does not
present a problem, but potential problems with wet glue
getting on operators fingers need to be addressed. If the
operators are able to handle and locate parts without
contaminating the clean surfaces there will be no problem, but
in some cases the operators will need to use special tools to
handle the parts, or wipe their fingers clean of glue at some
point in the gluing and assembly operation.
With machines designed to apply adhesive or coatings to the
top surface of the parts the issue of glue contamination is
drastically reduced.
The top surface of the part is coated, and the bottom side
remains clean for handling. Parts can be fed directly onto a
conveyer- (which is not possible with bottom-coated
parts). This can be important with large parts which would be
awkward to handle by the coated surface. Top Coating is
essential for parts which are being coated with a finish coat,
since the finish coat must have time to self-level and flow out
into a smooth coating after being applied.
F. Cleanup
With any roll coater, any adhesive remaining in the machine
after operation is complete must be cleaned completely or it
can dry on the rollers or other parts of the machine and cause
problems. Liquids which do not dry (such as oils) can be left
in the machine, as can most hotmelt adhesives, but other types
of adhesive and coatings must be cleaned out of the machine.
Ease of cleanup must be considered when selecting a roll
coater.
Most roll coaters are designed for quick cleanup, and may
incorporate features in their design to facilitate this aspect of
operation. Some design features that are used to make
cleanup easier are:
a) Wash down systems for rollers and tanks
b) Removable coating units
c) Easily removable tanks
d) Separate wash tanks
e) Built-in flush systems (often used on printing equipment)
f) Removable rollers
Roll Coater Selection
Once the factors described above are taken into consideration,
the choice of a roll coater suitable for the work to be done will
often be narrowed down to one or two machines. As each
question is answered, only one or two machines from any
manufacturer may fit the requirements, so by the time the
entire list of questions is reviewed, the choice of the best
machine for the job will usually be obvious.
In some cases questions about the suitability of a roll-coating
machine for a particular application still remains. In these
cases the best way to answer the questions is to run a test
using the roll coater, the adhesive, and the substrate together to
determine if they produce the desired results.
We shall review a few of them those are frequently use in
Flexible Packing, Adhesive Tapes, Adhesive Labels , or
other packing applications.
Gravure Coating
Metering Rod / Myer Bar Coating
Comma Coating
Hot Melt Coating Extrusion coating
To understand the process of coating on a substrate for the
manufacture of Packaging Material is quite simple .
The Adhesive/ Ink/ or specialty coating to be coated must have

good spread ability.
And let’s not forget one must have a right equipment to spread or
coat.
There are some of the other variable factors also involved , but we
shall look into coating methods Exclusively.
The Coating methods
Their Capabilities and Limitations
Coating Viscosity Max Speed Coating Wt .

Method in CPS per Min gm per sq. mtr
700
Gravure 100-2000 Mtrs. 3.-20.
Comma 1000-6000 300 10-200
Reverse Roll Nip 1000-6000 300 10-200
Reverse Roll Pan 200-6000 100 10-200

The Coating methods
Their Capabilities and Limitations
Hot Melt 500-20000 300 10-300

Myer Bar 10-200 200 3.-25.
Knife over Roll 100-20000 1500 3.-15.
Slot Orifice 500-20000 200 20-100
Immersion / Dip Coating 1000-10000 50 Heavy
Curtain 500-20000 200 20-100

Gravure Coating
The gravure coating process relies on an engraved roller running in

a coating bath, which fills the engraved dots or lines of the roller
with the coating material.
The excess coating on the roller is wiped off by the Doctor Blade
and the coating is then deposited onto the substrate as it passes
between the Engraved roller and a Pressure Roller.
There are three different ways of gravure roll manufacturing . One

has to choose a correct type depending upon the required coating
gram mage and the material to be coated
Gravure Coating Capabilities
Viscosity Range : 10 - 2000 Cps

Web Width Range : 300 – 2500mm
Coat Weight Range : 1 – 5gsm (Offset Gravure)
: 3-20gsm (Direct Gravure)
: 10 – 100gsm(reverse Gravure)
Substrates : Paper, Film And Foil.
Gravure Coating
The Process :
The Main Components:
Coating Tray / Pan
Gravure Roller (Etched Metal roller)
Doctor Blade
Impression Roll (Rubber roller)
The Process:
Pick up of Coating from the Pan
Fill up the Cells in the gravure roller
Wipe out the excess coating by Doctor Blade
Transfer the Coating to the Web
Empty the Gravure Cells after Transferring to Web
In Gravure Coating
method
The Applicator Pan or the Gravure
Tray Plays a very Roll
Important Role
The Adhesive level has to

be maintained Constantly Adhesive IN Adhesive OUT
The Foam generation has
to be minimized
No settling of Solids
This is Possible with some
of the tray Designs shown
in the figure
Gravure
Roll
Adhesive IN
Adhesive OUT
The Gravure Roller performs important Functions
Apply continuous and homogeneous coating across

and down the web
The etching pattern determines the coating weight
It is a driven toll to manage web tension
At times it is hollow with water circulation to maintain

coating temp and the viscosity of the coating
In low weight coating or printing, anilox is a method used to
provide a measured amount of ink to a flexo printing plate.
An anilox roll is a hard cylinder, usually constructed of a steel
or aluminum core which is coated by an industrial
ceramic whose surface contains millions of very fine dimples,
known as cells. Depending on the design of the printing press,
the anilox roll is either semi-submerged in the ink fountain, or
comes into contact with a so-called metering roller, which is
semi-submerged in the ink fountain. In either instance, a thick
layer of typically viscous ink is deposited on the roll. A doctor
blade is used to scrape excess ink from the surface leaving just
the measured amount of ink in the cells. The roll then rotates to
contact with the flexographic printing plate which receives the
ink from the cells for transfer to the printed material.
The characteristics of an anilox roll determine the amount of
ink that will be transferred to the plate: angle of the cells,
cell volume, and line screen. A 60 percent angle ensures
maximum density in a given space. Lower volume makes for
less ink. Low line numbers will allow for a heavy layer of ink
to be printed, whereas high line numbers will permit finer
detail in printing. Both cell volume and line screen are closely
correlated.
Anilox rolls are often specified by their line screen, which is
the number of cells per linear inch. These often range from
around 250 to upwards of 2000, though the precise numbers
vary by manufacturer. Most rolls sold are within 800 LPI,
although a spike in demand for those with 800-1200 lines has
been seen. Anilox rolls are almost always designed to be
removed from the press for cleaning and for swapping out with
different line screen rolls.
Depending on the detail of the images to be printed, the press
operator will select an anilox roll with a higher or lower line
screen. Low line screen rolls are used where a heavy layer of
ink is desired, such as in heavy block lettering. Higher line
screens produce finer details and are used in four-color
process work such as reproducing photographs. Often a job
will require a different line screen for each color to be printed.
Experienced press operators are skilled at determining the
appropriate anilox rolls for a given print job.
Though large wide-web flexo rolls are only maneuverable by
overhead crane, on smaller presses anilox rolls are often
handled directly by operators. Extreme caution must be taken
when handling these pieces of hardware as a single bump
against a hard surface or sharp corner can destroy the delicate
cell structure on the surface and render a roller completely
useless,
at a cost of around US$5000 for even small narrow-web
rollers. Nicks and scratches add up quickly, so fine brushes
(never brass brushes) are used for cleaning the anilox roll.
Similarly, anilox rollers that are used with water, solvent and
oil based inks, which dry when left sitting out and unagitated,
must be cleaned immediately after use or a problem known as
plugging occurs, where minuscule amounts of ink dry in the
cells. This leaves tiny, but unacceptable, pinholes in anything
printed from the roll in the future.
Anilox rolls were originally made using a diamond pecking
machine, but modern rolls are laser engraved.
Laser engraving, which is different from laser marking,[1] is
the practice of using lasers to engrave an object. Laser marking
on the other hand just discolors the surface, without cutting
into the surface.
The technique does not involve the use of inks, nor does it
involve tool bits which contact the engraving surface and wear
out. These properties distinguish laser engraving from
alternative engraving or marking technologies where inks or
bit heads have to be replaced regularly.
The impact of laser marking has been more pronounced for
specially designed "laserable" materials and also for some
paints. These include laser-sensitive polymers and novel
metal alloys.
The term laser marking is also used as a generic term
covering a broad spectrum of surfacing techniques including
printing, hot-branding andlaser bonding. The machines for
laser engraving and laser marking are the same, so that the two
terms are sometimes confused by those without knowledge or
experience in the practice.
Laser engraving of anilox rolls
Prior to 1980 anilox rolls were produced by a variety of
mechanical processes. These metal anilox rolls were
sometimes sprayed with ceramic to prolong their life in
theflexographic printing press. During the 1980s laser
engraving systems were produced which used a carbon dioxide
laser to engrave the required cell pattern directly into the
polished ceramic surface. Since then Q-switched YAG lasers
were used for a period as they provided a more focusable laser
beam as well as increased pulsing frequencies capable of
engraving the finer cell configuration demanded by the ever
evolving flexographic printing process.
Since approximately the year 2000 the direct anilox laser
engraving process has been dominated by the use of fibre
lasers which provide the high powers of the carbondioxide
lasers together with the finely focusable beam of the YAG
lasers. Optical systems providing the rapid switching of
multiple beams have allowed the fibre laser system to be
dominant in this market. This technology has become known
as Multi-Beam-Anilox or MBA.
CHARACTERISTICS OF
ENGRAVED GRAVURE ROLLERS
Type of Engraving Screen Cell Depth Deposit gm/m2

mm
Lines/in Lines/cm
Pyramidal 200 79 0.003 2.4

40 16 0.037 27.6
Quadrangular 200 79 0.005 3.6

16 6 0.065 49.5
Trihelical 120 47 0.010 11.7

24 9 0.055 63.1
The Most Common Gravure Cell Patterns
Pyramidal cells
Quadrangular
Tri helical
Pyramid Quadragravure
Roto-Flo Pyramid Quad Roto Flo
Tri-Helical Quad Channel

The Gravure Cell or Pattern creation
Cell Properties
BCM: Volume
( Billion Cubic Micron per Square Inch ) : 2 – 200 BCM
LPI: Cell Density = Lines Per Inch : 10 – 1500 LPI
Release / Transfer Rate : % Coating Volume

Released Onto Substrate
Method of Cell Creation :

Mechanical Engraving
Laser Engraving
Electronic Engraving
The Cell Pattern
Breadth = Y
Improve Release Property

Depth = X
Depth = X - less
Depth = X - less
Common Patterns in Laser Engraving
60o Hex 30o Hex
Tri-Helical 30o Channel

Common Patterns in Electronic
Engraving
Include Engraving Chart here
Doctor’s Blade , angle of Contact Trailing
Blade
Doctor’s blade Removes or Excess

Coating
Only the Coating filled up in the Cells
Gravure
remains
Roll The Cell Determines the Coat Weight
Angle of Contact : Trailing Blade is
meant for
Low Speed / Low Viscosity
Hydraulic Forces Can Lift Blade
Traps Contaminates
Loading Pressure
0.5 – 4.0 pli
Doctor’s Blade , angle of Contact
Reverse angle Doctor’s blade Removes or Excess
Coating
Only the Coating filled up in the Cells
remains
The Cell Determines the Coat Weight
Angle of Contact : Reverse Angle is
Gravure meant for
Roll
Increased Speed and Viscosity
Hydraulic Force Helps Hold Blade
Rejects Contaminates
Loading Pressure
0.5 – 4.0 pli
Coating application methods
There are several coating methods, but three are the most commonly used.
The blade coater rolls the liquid coating onto the bottom of the paper, then
uses a flexible blade to scrape away the excess coating. This method
produces a sheet with high gloss, but the resultant variation in coating
thickness can cause inconsistent ink holdout and produce uneven printed
solids (mottle).
The trailing blade coating method scrapes away excessive coating, but
leaves a thick-and-thin effect.
The trailing blade

coating method scrapes
away excessive coating,
but leaves a thick-and-
thin effect.
The Doctor Blade holder
assembly looks like the figure
below
Generally fitted with pneumatic

movement
The blade angle is changeable
The blade Oscillation system is
motor driven
The Backup or the Impression Roller
This is a Rubber roller

Width of this roller has to be slightly lesser than
the web width
The Rubber should be of Hardness 60-65 Shore A
Rubber Roller
WEB
Gravure Roller
The Hardness of the Roller has a Impact on the quality as
well as the quantity of coating
Higher Rubber thickness with a softer Hardness of around

60-70 shore A , generally gives more coating weight
Lower Rubber thickness with a higher Hardness of around

80-90 shore A , generally gives lower coating weight
For uniform coating across the web the Rubber roller needs
to be ground to precision.
Generally higher the rubber hardness more uniform is the
coating
The Gravure Coating can be further improved
with a system called as enclosed applicator
Rubber
Roll
Coated Web
Web
Gravure
Roll
Adhesive
Out Adhesive IN
Enclosed Applicator
Reverse Gravure
Reverse Application
Speed Range: 90-120%
Benefits
Removes Cell Pattern
Film Split Avoided
Minimizes Ribbing
Rubber
Adjust Coat Weight with Roll
Coated Roll Web
Speed Web
Impression Control is Critical
Light / Controlled Impression
Precision Required – Better Rolls
Gravure
Driven Impression Roll
Roll
Suggested for Tension Control
Overcome Reverse Action
offset Gravure
3-Roll System
Gravure is Offset from Substrate
Steel
Removes Substrate from Coating Nip Back
Protects Sensitive Substrates Coated up Roll Web
Web
Roll Rotation
All Roll Same Direction
Synchronous Rotation
Rubber
Two Film Splits
Roll
Thinner Coatings
Roll Speeds
All Rolls at 100% Line Speed
Single Drive is Possible Gravure
Gravure Roll is Typically Driven – Idle Mode Roll
Applicator Roll is Nip Driven
Back-up Roll is Web Driven
Kiss coating
In this method, coating is lifted up by the drive rolls soaked in
the paint pan, transferred to the top roll and then applied to
paper that is pressed against the top roll by the press roll.
Two side Coating at a Time
• Very Cost Effective
– Coat Both Sides at One
Coating Station
– Single Dryer vs. Dual
Dryers
– Reduced Overall Line
Length
• Direct Application (Kiss
Coating)
– Forward or Reverse Apply
– Coat Weight is Susceptible
to Tension Variations
• Limited Range of
Applications
– Thinner Coatings
– Same / Similar Functional
Coatings on Both Sides
Two side Offset Gravure coating
Two side Offset
Kiss
coating
Some Modifications of Gravure Printing
or coating
5-roll coating system
Extremely slight and precise coating weights are adjustable
Coating weight can be increased or reduced, up to 50%, by
changing one cylinder velocity during machine run
Accurate repeatability through high precision mechanical stops
with micro-adjustments
Specifications
Production speed up to 1500m/min (4900ft/min)
Coating width >3000mm possible
High precision cross profile over the whole web width of 2%
which is guaranteed by using a special cylinder technology with a
patented deflection compensated impression roll
Applications
solvent less coatings with 100% solids
thermal curing
UV curing
EB curing
5-roll coating head for solventless, 100% solids coatings.
The coating head is designed for a production speed of up to 1500

m/min.,
with a coating width of 1700 mm and is equipped with a patented

roll deflection compensating system.
This coating method is especially suitable for low coating weights

with high quality requirements in regard to the coverage and
coating weight tolerances at high production speed.
The precision presetting mechanism ensures highest accuracy in

repeatability of production parameters.
5-roll coating system
Extremely low and precise coating weights are

adjustable
Coating weight can be increased or decreased, up to

50%,
by changing one cylinder velocity during machine
run
Accurate repeatability through high precision

mechanical stops with micro-adjustments
or coating
• Gravure cum Kiss

coating method for very
low viscosity coatings
or coating
• Gravure cum reverse

roll coating type one
or coating
• Gravure cum reverse

roll coating type two
The Comma coating system is a spreader for processing of highly viscous
aqueous and solvent-containing adhesives.
In this process, the system is placed directly at a slightly lower heights as

compared to the Drying Tunnel .
It is done so to avoid running-off of the coating compound , as the coated web
enters the drying tunnel , allmost immediately after coating. Production is
possible with working widths between 600 and 1,650 mm and a speed up to 100
m/min.
This system consists of typically 2 rollers , in rare cases 3 rollers might be used
Features and Performance Characteristics:

Ensuring of a stable / uniform roller gap due to hydraulic positioning of the
comma blade
Fine-adjustment of the roller gap due to step motors
The coating / adhesive is poured directly on the web to be coated.
In this coating process, an excess of the coating is deposited
onto the substrate as it passes over the bath roller.
The wire-wound metering rod, known as a Meyer Rod,

allows the desired quantity of the coating to remain on
the substrate.
The quantity is determined by the diameter of the

wire used on the rod.
This process is remarkably tolerant of non-precision

engineering of the other components of the coating machine.
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The market for wire-wound rods has grown rapidly during the past few
decades, because they provide predictable, accurate coatings time after
time, at a minimal cost.
Although the technology goes back almost a century, today's high

quality materials, multi-wire designs and special wire surfaces have
made this system more popular than
ever before.
Rods give users the ability to fine-tune coating thickness quickly and
easily, without altering the chemistry of their coating material, and
without time-consuming and expensive changeovers.
Wire-wound rods were first used in coating machines built by Charles
Mayer in the 1900's to manufacture waxed paper and carbon paper.
They are still called “ Mayer Bars “ by many coaters.
Wet coating thickness can be accurately predicted within one tenth of a

mil (.0001").
Rod selection tables allow coaters to consider coat weight and percent
of solids in choosing the proper rod size for each production run.
Bottom-line profits have encouraged many coaters to modify existing

machines, in order to take advantage of the flexibility, the ease of use
and the dollar savings associated with rod coating.
One of the more common methods of coating is the Mayer rod
coater, sometimes called a metering rod coater. This equipment
has advantages such as low capital cost, ease of coat weight
adjustment, ease of operation, and a broad range of coat weights
are possible.
: Mayer Road Coater
In this coating method, an applicator roll delivers adhesive to the

substrate being coated. The applicator roll may turn either with or
against the primary web, delivering an excess of adhesive. Wire
wound rods are then used to remove the excess. The rods may also
turn in either direction.
The amount of adhesive removed depends upon the diameter of the

wire which is wound around the steel rod. Coat weight is increased
by simply switching to a rod wrapped with larger diameter wire. Two
rods in series often give better coating results than a single rod.
The first rod has larger diameter wire and removes most of the excess
adhesive. The second rod, with smaller diameter wire, smoothes the
coating and produces the final desired coat weight. Mayer rod
coating can deliver a broad range of coat weights.
TWO-WIRE DRAWDOWN RODS
Where heavier coatings are required, manufactures provide special

drawdown rods with two wires. A standard single-wire rod is over wound
with a smaller wire which follows the spiral of the base wire. The result is
a modified groove between the wires that will produce wet coatings up to
19 mils (.019") thick.
TRI-WIRE DRAWDOWN RODS
Three Rod technology developed by for Coatings up to 56 mils (.056") thick can
be produced, using three standard wires wound in a unique configuration.
Two wires are wound side by side on a core rod, then a third wire follows one
spiral of the base wires. The resulting groove will maximize the area between the
wires, producing a coating more than six times the thickness produced by a
single-wire rod!
Metering Rod Application Chart
Thickness(1) Coverage Wet Film Weight
Rod # Mils Microns Ft2/gal m2/l lbs/1000ft2 g/m2
1 0.15 3.8 10,700 263 0.94 3.8
3 0.3 7.6 5,350 131 1.87 7.6

4 0.4 10.2 4,010 98.4 2.49 10.2
5 0.5 12.7 3,210 78.7 3.12 12.7
6 0.6 15.2 2,670 65.6 3.74 15.2
8 0.8 20.3 2,010 49.2 4.99 20.3
10 1.0 25.4 1,600 39.4 6.23 25.4
12 1.2 30.5 1,340 32.8 7.48 30.5
15 1.5 38.1 1,075 26.3 9.36 38.1
18 1.8 45.7 891 21.9 11.2 45.7
22 2.2 55.9 727 17.9 13.7 55.9
30 3.0 76.2 535 13.1 18.7 76.2
Metering Rod Application Chart
Thickness(1) Coverage Wet Film Weight
Rod # Mils Microns Ft2/gal m2/l lbs/1000ft2 g/m2
42 4.2 107 382 9.2 26.2 107

50 5.0 127 320 7.9 31.2 127
80 8.0 200 201 4.9 50.0 203
100 10.0 254 160 3.9 62.3 254
cut angle comma coating way comma reverse coating way
Applicable conditions: Applicable conditions:

viscosity 1000 ~ 20000CPS viscosity 1000 ~ 20000CPS
Coating amount of 10 ~ 20000g/m² Coating amount of 10 ~ 20000g/m²
Comma direct coating
This method is a kind of knife coating, and a cutting blade
similar to the one used for knife coating is incorporated into
a part of the rod. This method is characterized by very high
processing accuracy and the capability of processing a
solution whose viscosity is as high as several thousand cps.
Conversely, a processing solution with very low viscosity
requires a viscosity adjustment to prevent leakage. The
characteristics of the finished coating surface are that the
irregularities on the base material surface are filled to make
the coated surface smooth. In addition, this method is
suitable for processing expensive chemicals because the
processing solution in the pan can be completely used up.
Comma reverse coating
In the comma direct coating method, a processing solution is
applied directly to paper. On the other hand, in the comma
reverse coating method, a processing solution is once applied
to rolls and then the processing solution that came out
between the rod knife and roll with adjusted clearance is
transferred to a paper or nonwoven fabric. This has the
advantage that it is possible to apply a certain amount of
processing solution accurately.
5 Roll Comma Coating Station
Coating films with thickness of under 1 µm can be achieved

with 5 roller system. This application is used e.g. for the
production of siliconized papers.
The Reverse coating system is a spreader for processing of highly
viscous aqueous and solvent-containing adhesives.
In this process, the system is placed directly at a slightly lower
heights as compared to the Drying Tunnel .
It is done so to avoid running-off of the coating compound , as
the coated web enters the drying tunnel , allmost immediately after
coating. Production is possible with working widths between 600
and 1,650 mm and a speed up to 100 m/min. This system consists
of typically 3 rollers .
Features and Performance Characteristics:
Ensuring of a stable / uniform roller gap due to hydraulic
positioning of the comma blade Fine-adjustment of the roller gap
due to step motors . The coating / adhesive is not poured directly
on the web , and a metered film of wet adhesive comes in contact
with the web to be coated , at the other nip formed between backup
and applicator roller.
In this procedure, the coating material is measured onto
the applicator roller by precision setting of the gap between
the upper metering roller and the application roller below it.
The coating is 'wiped' off the application roller by

the substrate as it passes around the
support roller at the bottom.
The diagram illustrates a 3-roll reverse roll coating process,

although 4-roll versions are common.
Reverse Roll Coater
The three roll reverse coater is used for many specialty applications.
This method is more expensive and generally slower in line speed
than the Mayer rod coater.
However, the versatility in terms of coat weight range and coating

width, and the good coat quality of the three roll reverse has made it
popular with many converters.
In this process, the middle roll is coated with a precise thickness of

adhesive, determined by the size of the gap between the top and
middle rolls.
The adhesive is then transferred as the rubber backing roll brings the
web into contact. The adhesive coat weight can also be varied by
increasing or decreasing the speed of the applicator roll relative to the
web speed. The metering roll speed can be varied to adjust the
smoothness of the coating.
Figure 2 : Reverse Roll Coater
There are several variations of the reverse roll coating method, such
as four-roll,
nip fed, and pan fed systems. A nip-fed, three roll reverse coater is
shown here.
Medium to high coat weights are possible with reverse roll.
Reverse roll coating is a roll-to-roll coating method for wet coatings. It is
distinguished from other roll coating methods by having two reverse-running nips. The
metering roll and the applicator roll contra-rotate, with an accurate gap between them.
The surface of the applicator roll is loaded with an excess of coating prior to the
metering nip, so its surface emerges from the metering nip with a precise thickness of
coating equal to the gap. At the application nip, the applicator roll transfers all of this
coating to the substrate, by running in the opposite direction to the movement of the
substrate, wiping the coating onto the substrate.
Reverse roll coating machines demand high specifications in their construction, e.g. for
the machining and bearings of the rollers and for highly uniform speed control. This
makes them relatively expensive compared to other coating technologies. Unlike many
other coating methods, they can however handle coatings with a very wide range of
viscosities, from 1 to more than 50000 mPas, and are capable of producing extremely
polished finishes on the coatings they apply. They have been produced in a variety of 3-
roll an 4-roll configurations.[1]
Products manufactured on reverse roll coating machines include Magnetic Tapes; Foam
fabrics; electrographic reproduction papers and pressure sensitive tapes. The rise of
slot-die coating has tended to eclipse reverse roll coaters as in most if not all cases, the
same products can be made on cheaper machinery.
VISCOSITY RANGE
150 - 150,000 Cps
WEB WIDTH RANGE

300 - 2500mm
COAT WEIGHT RANGE

10 - 200gsm wet
TYPICAL SUBSTRATES
Paper, film and fabric
Hot Melt Coating
Hot Melt
Adhesive
The coated
product is
Application
cooled down
of heat upto
to RT.
160 deg C
Adhesive is
back to solid
Liquid is
Adhesive
coated using
melts and
special
becomes
nozzles /
Liquid
roller / Die
The name itself suggests these type of adhesives.
Hot Melt Coating
A adhesive which melts on application of heat is called as Hot Melt
Adhesive
Hot melt adhesives are thermoplastics, based on polymers that
become liquid between temperatures of 80 – 220 °C and solidify
again by cooling down.
They consist of 100 % dry substance and are applied in liquid state
without using water or solvents.
With respective pre-melt systems, pumps and application units (slot
die, hot roller and powder scattering) an exact dosage and
adjustment is possible.
Due to the process only a short binding and setting time is
requested in comparison with dispersions or solutions.
In the Slot Die process, the coating is squeezed out by
gravity or under pressure through a slot and onto the
substrate. If the coating is 100% solids, the process
is termed 'Extrusion' and in this case, the line speed is
frequently much faster than the speed of the extrusion.
This enables coatings to be considerably thinner than
the width of the slot.
Slot Die Coater
The slot die coater does not use rollers to deliver the adhesive to the
web.
Instead, adhesive is pumped into a chamber, where it exits through a
long, narrow slot directly in contact with a moving web. The web is
usually supported immediately behind the slot with a rubber or steel
backing roll.
Figure 4 : Slot Die Head Set-Up

The slot die coating method is inherently low foaming, and is capable
of producing good quality material at high line speeds. However, the
equipment is relatively expensive and requires a high level of
operator expertise. Moderate to high coat weights are possible with
slot die.
Extrusion Coating Lamination
- It can be used on various

substrates as paper, cotton
cloth, woven fabrics, jute
fabric, aluminium foil, Bopp
film or even a polyester film.
- Can perform either

extrusion coating or extrusion
lamination.
- Highly efficient and durable

lamination.
Extrusion lamination is a process that is used to combine two different substrates
using molten polymers.
The process of extrusion lamination metal, paper and mainly plastic films. It
can provide lamination of different thicknesses with level of quality. includes both
the characteristics of extrusion and lamination.
process to coat an additional layer on existing roll stock of paper, cotton cloth,
woven fabrics, jute fabric, aluminum foil, Bopp film or polyester film.
This process can be used to improve the characteristics of paper by coating on it
with polyethylene to make it more resistant to water.
The extruded layer can also be used as an adhesive to bring two other materials
together.
Film Extrusion,
Extrusion Coating,
and Lamination
Processes
Extrusion laminating (also known as sandwich laminating) is a process related
to extrusion coating, but the extrusion-coated layer is used as an adhesive layer
between two or more substrates.
A secondary layer is applied to the extrusion coating while it is still hot. The
MP50 monitors the melt curtain before the chill roll before the sandwich is
formed.
The sandwich is then pressed together by pressure rolls.
In addition to providing adhesion, the extrusion-coated layer may also serve as a
moisture barrier.
Extrusion Coating
SOME APPLICATIONS OF EXTRUSION COATING AND
LAMINATION
End Products Laminated Coated

Sr No. Substrate Type of Lamination
Applications With
HDPE/PP woven sacks HDPE/PP woven LDPE or PP

1 Single sided
and tarpaulins fabric 15-50 micron
PP/HDPE woven for

sack laminated with Kraft paper upto 200
2 paper for packing of gsm & HDPE/PP LDPE/PP Sandwich
cement, fertilizers, woven sack
polymers
LDPE
3 Soap wrapper Paper Single sided
20-40 micron
Paper & Aluminium
4 Medical tablet strips LDPE 25 micron Sandwich
foil
'Brick' pack for soft

White paper, Kraft
5 drinks, juices, milk, oil LDPE 7 layer sandwich
paper, Aluminium foil
etc.
Slot Die section view
displaying internal manifold
Slot-Curtain Coating
section displaying
Manifold and Transfer
Flows
Commercial Advantages
Precision Die Coating allows

participation in higher-margin markets exclusive
to superior product
functionality and more frugal manufacturing
(reduced waste, higher productivity)
when compared with other coatings methods
such as roll, blade, gravure, rod, etc.
Slot-bead Coating with
applied vacuum.
Transfer flow of slot-bead

coating
Slot Die section view displaying

internal manifold
we shall now review a few of the other coating methods , not
being used so commonly , but for some specific application.

Calendaring
Immersion / Dip coating
Curtain Coating
Immersion (Dip) Coating
In this simple process, the substrate is dipped into a bath
of the coating, which is normally of a low viscosity to
enable the coating to run back into the bath as the
substrate emerges. This process is frequently used on
porous substrates.
Dip coating, along with brush coating and wire wound rod coating, is one of the oldest
coating methods. There are two basic dip coating process concepts. In the web coating
process, the substrate is partially submerged into a coating pan containing the solution to
be coated and a wet film is withdrawn onto the moving web, Figure 1. In the discrete
method, the irregularly shaped discrete objects to be coated, nails, circuit boards,
architectural steel members to optical components are inserted into a tank containing the
coating solution. As it is withdrawn a film is attached to the part, which is then dried, so
that the part is useable.
The continuous web coating process is still widely used because of the following reasons:
• It can apply a range of coating thickness with reasonable coating quality.
• The coating equipment is inexpensive and relatively simple to operate.
• High-speed capability of the process should lead to low costs and high
productivity.
• Scale-up from laboratory coaters is much easier than for precision coaters such
as slot-die and curtain coating.
• Excess coating material can be removed by doctoring devices such as Mayer
Rod, Air Knife, blades, and squeegee rolls to allow wide range of coating weights.
• Understanding the limits of dip coating is important to understanding the
behavior of many other coating techniques
The wet thickness for the unassisted dip coater is determined by:
• Fluid properties
• Coating speed
• Withdrawal angle.
The range of operating parameters for dip coating are as follows:
Viscosity 20–2000 cP or mPa-s
Wet thickness 10–200 μ (0.4-8 mil)
Line speed 0.5–7.5 m/s (100–1500 fpm)
Coverage uniformity ± 10 %
The wet coating thickness increases with viscosity and coating speed. Therefore, when
thin coatings are required at high speeds and viscosity a doctoring device is needed to
obtain the desired coverage.
Dip coating, along with brush coating and wire wound rod
coating, is one of the oldest coating methods. There are two basic
dip coating process concepts. In the web coating process, the
substrate is partially submerged into a coating pan containing the
solution to be coated and a wet film is withdrawn onto the
moving web, Figure 1. In the discrete method, the irregularly
shaped discrete objects to be coated, nails, circuit boards,
architectural steel members to optical components are inserted
into a tank containing the coating solution. As it is withdrawn a
film is attached to the part, which is then dried, so that the part is
useable.
The continuous web coating process is still widely used because
of the following reasons:
• It can apply a range of coating thickness with reasonable
coating quality.
• The coating equipment is inexpensive and relatively
simple to operate.
• High-speed capability of the process should lead to low costs
and high productivity.
• Scale-up from laboratory coaters is much easier than for
precision coaters such as slot-die and curtain coating.
• Excess coating material can be removed by doctoring devices
such as Mayer Rod, Air Knife, blades, and squeegee rolls to
allow wide range of coating weights.
• Understanding the limits of dip coating is important to
understanding the behaviour of many other coating techniques
The wet thickness for the unassisted dip coater is determined by:
• Fluid properties
• Coating speed
• Withdrawal angle.
The range of operating parameters for dip coating are as follows:
Viscosity 20–2000 cP or mPa-s
Wet thickness 10–200 μ (0.4-8 mil)
Line speed 0.5–7.5 m/s (100–1500 fpm)
Coverage uniformity ± 10 %
The wet coating thickness increases with viscosity and coating

speed. Therefore, when thin coatings are required at high speeds
and viscosity a doctoring device is needed to obtain the desired
coverage.
Dip Squeeze Coating
This coating method is for coating a

liquid of a predetermined concentration in
the tray, soaking a paper or non-woven
fabric with the liquid coating , and
squeezing excess coating with the
squeezing rollers to coat the required coat
weight.
It is characterized by the ability of

processing various kinds of materials,
such as water-soluble resin, emulsion
resin, solvent resin, and compound resin
for filler and pigment easily.
In general, base materials requires the wet

strength of 0.5–0.7 kgf/25 mm or higher.
Curtain Coater
A curtain coating head functions very similarly to a slot die coater except that the
slot is position several centimeters above the moving web, and edge guides are used
to control the width of the falling curtain. With carefully designed emulsion
properties such as rheology and surface tension, acrylic emulsion pressure sensitive
adhesives may be coated via curtain coater at speeds in excess of 1000 meters per
minute. Elimination of foam in the adhesive is also critical to achieving maximum
line speeds with this method.
Curtain Coating
In the Curtain Coating process, a bath with a slot in the base
allows a continuous curtain of the coating to fall into the gap
between two conveyors. The object to be coated, such as a door,
is passed along the conveyor at a controlled speed and so
receives the coating on its upper face. Smelly and crude versions
of these machines were once common.
This process relies on a coating being applied to the substrate which
then passes through a 'gap' between a 'knife' and a support roller.
As the coating and substrate pass through, the excess

is scraped off.
This process can be used for high viscosity coatings and very high
coat weights, such as plastisols and rubber coatings.
There are innumerable variants of the relatively simple process

which is rugged, hard-working and somewhat inaccurate.
knife coating process can be used to apply coatings to substrates and
materials like foams, woven textiles, non-wovens, and paper. In applying
coatings using the knife coating method, we can work with substrates up to
80” wide, with weights between 1 oz. and 60 oz./sq. yd.
Knife coating is a method of coating application where the substrate

material is fed on a web over a roll, with a knife set to a predetermined gap
height. When the coating is applied to the substrate and fed through, the
knife removes the excess coating material, resulting in an even application
at the desired thickness.
Knife coating is useful when applying adhesives and other coatings for the
paper, laminating, automotive and other industries.
This is the coater of choice when the requirement is for very heavy and
level coating of medium to high viscosity onto uneven surfaces such as
textiles, fibreglass mats and non-wovens. Typical applications include pre
impregnated composite fibres, embossed and plain flooring, reinforced
plastics and medical dressings.
Key features include:
Rugged construction to handle the high hydrodynamic forces
High precision backing roll manufactured to 5μ TIR or better
Gap setting based on pneumatically loaded wedge system adjusted by
backlash free micrometer ball screws actuated via servo drives
Option available:
A heated backing roll, blade and dam system.
VISCOSITY RANGE
500 – 50,000 cps
WEB WIDTH RANGE
300 – 2500mm
COAT WEIGHT RANGE
100 – 1000gsm wet
TYPICAL SUBSTRATES
Paper and fabric
Knife over Roll Coater
Air Knife Coating
Air Knife Coating A simple process where the coating is applied to the
substrate and the excess is 'blown off' by a powerful jet from the air
knife. This procedure is typically used for aqueous coatings and is
particularly noisy.
The Air Knife coater, also called Air Doctor is an example of an
old coating method that is still widely used and has a role in the coating
process. It was widely used to sequentially coat the multiple layers needed
for photographic films because it could apply thin layers from low viscosity
solutions. Slide and curtain coating because of improved quality, higher
speeds and multilayer capability replaced it. It is now widely used to apply
pigmented coatings in the paper industry and for 100% solids coating such
as molten zinc and aluminum in galvanizing applications
In this method a coating roll and pan are used to apply the coating solution
to the web and then an air knife is positioned after the pan to regulate the
final wet-coating weight by applying a focused jet of air to the web. The
excess solution is collected in an overflow pan and can be either
recirculated and used again or scrapped. Figure (1) is a typical air knife
configuration.
The advantage of the air-knife processes are low initial cost, versatility for
aqueous coating of coating a variety of webs and solutions, ease of
changing and maintaining the coating and the good coating quality. The
disadvantages are line speed and coating weight limitations, noise , solution
viscosity limitations, and susceptibility to streaks and chatter.
The air knife can function either in the precision or in the squeegee mode.
These give very different types of coating and performance characteristics,
although the same name is used for both processes.
In the precision mode, the air knife uses low pressures and doctors off some
of the coating to control the coating weight and to level the surface to give a
uniform coating of reasonable quality. The coating weight is a function of
web speed, viscosity of solution, surface tension and air-knife pressure and
the Coating profile is the same as that of the substrate.
The process operating conditions are as follows:
• Viscosity 1 - 50 centistokes
• Wet thickness 1 - 200 microns
• Line speed 14:31:09 40 - 400 fpm
• Accuracy +/-10%
In the squeegee mode, the air knife operates at much higher pressures and
coating speeds than in the precision mode and effectively doctors off the
majority of the coating. This process is used for porous supports, such as
paper, where the coating is absorbed into the voids. After the air knife,
which effectively functions as a leveling device, the coating solids remain
in the voids and in a thin surface layer.
An air knife is a tool used to blow off liquid or debris from
products as they travel on conveyors. Air knives are normally
used in manufacturing or as the first step in a recursive
recycling process to separate lighter or smaller particles from
other components for use in later or subsequent steps, post
manufacturing parts drying and conveyor cleaning, part of
component cleaning. The knife consists of a high intensity,
uniform sheet of laminar airflow sometimes known
as streamline flow.
An industrial air knife is a pressurized air plenum containing a
series of holes or continuous slots through which pressurized air
exits in a laminar flow pattern. The exit air velocity then creates
an impact air velocity onto the surface of whatever object the air
is directed. This impact air velocity can range from a gentle
breeze to greater than Mach 0.6 (40,000 ft/min) to alter the
surface of a product without mechanical contact.
Air knives remove liquids, control the thickness of liquids, dry
the liquid coatings, remove foreign particles, cool product
surfaces or create a hold down force to assist in the mechanical
bonding of materials to the surface. Electrical currents from
anti-static bars can also be injected into the exit air knife stream
to neutralize the static electricity charge on some surfaces.
In the majority of manufacturing applications for air knives, the
air knives are stationary while the product passes through the air
velocity air stream. In other circumstances, the product is
stationary and the air knives move (reciprocate or rotate) over
the surface of the stationary product. Although there are very
few applications where an air knife can actually cut a product
(break mechanical bonds between two points), air knives are
often the most efficient method of removing or controlling
unwanted or foreign substances on any surface.
Description of operation
Air knives on a production line commonly range from 0.25 to
200 inches (6.4 to 5,080.0 mm) in length with a discharge air
slot or holes ranging from 0.001 to 0.25 in (0.025 to 6.350 mm).
A stationary air knife configuration can require from one to a
dozen air knives depending on the application criteria. Air is
blasted through the air knife slots via an air generator, either an
industrial blower or air compressor, to deliver the predetermined
exit air volume and velocity needed.
There are many application, environmental, efficiency and duty
cycle aspects to consider when choosing between compressors
and blowers. Compressed air, which is least efficient when used
for air knives discharging into free air, allows for use of primary
plant air. The piping sizes supplying the air knives can be as
little as 1⁄4 in (6.4 mm) diameter so they are ideal for confined
spaces.
Blower powered air knives must be larger in size along with
larger diameter supply piping, but the efficiency improvement
over compressed air is easily justified with the electrical power
cost savings.
Air knife designs today have evolved to where some
manufacturers produce a very efficient “teardrop” shape with a
.95 coefficient of discharge. These blower powered air knife
designs typically have a profile of approximately 3.5 in (89 mm)
wide x 5.5 in (140 mm) tall x any length, but the teardrop profile
can range from 1.5 to 10 in (38 to 254 mm) tall depending on
the criteria of the product for which the impact air velocity must
be engineered. With construction ranging from 1⁄8 in (3.2 mm)
thick aluminum extrusion to 11 gage fabricated stainless steel,
air knives can weigh 1 lb/ft to 25 lbs/ft. Depending on the width
and speed of the product, the air knife can provide effective
blow off performance from 0.5 to 12 in (13 to 305 mm) or more
away from the surface of the product.
Round air nozzles of 1 to 4 in (25 to 102 mm) diameter can be
effective against surfaces which are up to several feet (1 to 2
meters) from the product surface when engineered for such
applications.
Types and applications
The most common use of air knives is to contain or remove
free-standing materials (liquids or solids) from the surface of
material. The applications include drying bottles and cans after
filling and rinsing, printed circuit boards following the conveyor
zed wash to remove solder paste and flux, metals castings after
automatic machining and many more. They can also deliver
heated or cooled air to a surface, or create an invisible air barrier
to separate heated or cooled environments from one another in
industrial applications such as continuous metal heat treating
ovens, cold process or storage areas in food processing or dust
containment for the entrance to clean rooms.
There is a variety of uses for air knives in many different
industries, applications and environments. The invisible high
velocity air streams can be discharged by air knife designs of
numerous shapes and sizes. These range from “garage built”
devices with a low level of precision to the most exotic metals
of construction used in air knives for class 100 clean rooms.
In instances where noise reduction and moisture containment
around a conveyorized air knife installation becomes important
some manufacturing facilities have installed air knives within an
enclosure. These enclosures keep water contained, reduce the
amount of air knife noise and even eliminate any liquid that
could create safety concerns.
Basic design features
Compressed air powered air knives
There has always been a wide assortment of blow off
appliances. Air knives and nozzles for compressed air blow off
range from home made round pipes with holes to engineered
high pressure air knives. In order to achieve the highest
efficiency using compressed air, many manufacturers of
compressed air knives utilize the Coandă effect to improve
compressed air knife design over other types of knives and
nozzles. Although the efficiency of compressed air for low
pressure blow off air is much lower than blowers, the Coanda
inspired air knives entrain ambient air into the high velocity
stream to enhance the blow off effect.
Blower powered air knives
The tear drop shaped air knife having a bulbous plenum which
tapers down to a precise air discharge slot as the standard of the
blower driven air knife industry. Whereas a round pipe with
holes drilled has an average coefficient of discharge of 0.6 (60%
efficient), the tear drop shape air knife is commonly 0.95 (95%
efficient) which provides much higher impact air velocity to the
surface at which the air is directed with the lowest blower motor
power demand. These tear drop designs are available in
extruded aluminum shapes as well as fabricated carbon and
stainless steels.
A second coating method solves this problem of an inconsistent coating
thickness. The air knife coating method uses a strong blast of air to
remove excess coating and leaves a layer of uniform thickness, but a
sheet with poor smoothness and reduced gloss. Of course, the sheet will
become smoother after being polished during the supercalendering stage,
but it will still not attain a high gloss level.
The air knife coating method

replaces the blade with a strong
blast of air. The result is a sheet
with consistent coating
thickness, but low smoothness.
An air knife is a tool used to blow off liquid or debris from products as they
travel on conveyors. Air knives are normally used in manufacturing or as the
first step in a recursive recycling process to separate lighter or smaller
particles from other components for use in later or subsequent steps, post
manufacturing parts drying and conveyor cleaning, part of component
cleaning. The knife consists of a high intensity, uniform sheet of laminar
airflow sometimes known as streamline flow.
An industrial air knife is a pressurized air plenum containing a series of
holes or continuous slots through which pressurized air exits in a laminar
flow pattern. The exit air velocity then creates an impact air velocity onto
the surface of whatever object the air is directed. This impact air velocity
can range from a gentle breeze to greater than 0.6 (40,000 ft/min) to alter
the surface of a product without mechanical contact.
Air knives remove liquids, control the thickness of liquids, dry the liquid
coatings, remove foreign particles, cool product surfaces or create a hold
down force to assist in the mechanical bonding of materials to the surface.
Electrical currents from anti-static bars can also be injected into the exit air
knife stream to neutralize the static electricity charge on some surfaces.
In the majority of manufacturing applications for air knives, the air knives
are stationary while the product passes through the air velocity air stream. In
other circumstances, the product is stationary and the air knives move
(reciprocate or rotate) over the surface of the stationary product. Although
there are very few applications where an air knife can actually cut a product
(break mechanical bonds between two points), air knives are often the most
efficient method of removing or controlling unwanted or foreign substances
on any surface.

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We Promise to attend your Technical need

Coating Process Technology is in widespread use.

Different types of coatings methods are used depending upon

The application of a liquid to the traveling web / substrate is

The coating method should be chosen based on the specific

There are three basic types:

• Self-Metered : Here in the coating equipment controls the

• Doctored : Here in the applied coating is metered lateron or

• Pre-metered : Here in all fluid fed to applicator transfers to

Selecting an appropriate coating method is a challenge because

The typical approach to selecting the coating method for a new

This loss is minimal for a high volume long coating campaigns.

Air knife metering mode Comma direct/indirect Curtain Precision

This information is very useful to select a method most

A discussion of rollers for the adhesives and sealants sector

Coating rolls are virtually always covered (seldom just bare

This saves money vs. completely recovering the roller every

High-release silicone is another popular option for coating rolls,

The final item all engineers should note is balance. Whether

Don’t underestimate the importance of your plant’s rollers.

Reverse Roll Coating

The Adhesive/ Ink/ or specialty coating to be coated must have

Their Capabilities and Limitations

Coating Viscosity Max Speed Coating Wt .

Comma 1000-6000 300 10-200

Reverse Roll Nip 1000-6000 300 10-200

Reverse Roll Pan 200-6000 100 10-200

Their Capabilities and Limitations

Hot Melt 500-20000 300 10-300

Knife over Roll 100-20000 1500 3.-15.

Slot Orifice 500-20000 200 20-100

Immersion / Dip Coating 1000-10000 50 Heavy

Curtain 500-20000 200 20-100

The gravure coating process relies on an engraved roller running in

There are three different ways of gravure roll manufacturing . One

Viscosity Range : 10 - 2000 Cps

The Adhesive level has to

Apply continuous and homogeneous coating across

The etching pattern determines the coating weight

It is a driven toll to manage web tension

At times it is hollow with water circulation to maintain

Type of Engraving Screen Cell Depth Deposit gm/m2

Pyramidal 200 79 0.003 2.4

Quadrangular 200 79 0.005 3.6

Trihelical 120 47 0.010 11.7

Roto-Flo Pyramid Quad Roto Flo

Tri-Helical Quad Channel

LPI: Cell Density = Lines Per Inch : 10 – 1500 LPI

Release / Transfer Rate : % Coating Volume

Method of Cell Creation :

Improve Release Property

60o Hex 30o Hex

Tri-Helical 30o Channel

Doctor’s blade Removes or Excess

The trailing blade

Generally fitted with pneumatic

This is a Rubber roller

Higher Rubber thickness with a softer Hardness of around

Lower Rubber thickness with a higher Hardness of around

The coating head is designed for a production speed of up to 1500

with a coating width of 1700 mm and is equipped with a patented

This coating method is especially suitable for low coating weights

The precision presetting mechanism ensures highest accuracy in