double sided coating methods for paper and films · this presentation will outline double sided...
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Double side coating methods for paper and films
Joerg Pahle-Kraas
&
Ralph Pagendarm
AIMCAL FTC 2011
SAM Sungan Ralph Pagendarm
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Content
• Introduction
• Coating Methods
• Double Side Coating
• Dryers
• Single Side Coating Line
• Double Side Coating Line
• Conclusion
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Worldwide competition forces film manufacturers to offer added value to their film production lines
Many products of paper and films are double side coated.
Conventionally this is done in 2 steps with intermediate drying and web guiding.
This presentation will outline double sided coating methods for paper
and film, which are done simultaneously – without intermediate drying.
Advantages are manifold as cost savings, shorter web length, easier
operation.
Introduction
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Front and back side coating with same or different coating fluids are possible
Front and back side coating weights could be the same or different
Common solutions are: direct and indirect gravure coating, typically with kiss coat transfer combined with air floatation dryer. The air floatation dryer guarantees perfect web stability for a wide operation range of web tension and air flow.
Air floatation dryer with perfect web stability ad a wide operating window
Introduction Double Side Coating
What can be acclompished with a suitable double side coater?
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Coating Methods Single Side Double Side Gravur (Anilox) Roll direct
Kiss Backing Roll
√ √
√
√ (1.coating) Gravur (Anilox) Roll indirect
Kiss Backing Roll
√ √
√
√ (1.coating) Spray √ (√) Mayerbar
Kiss Fountain Die
√ √
√ √
Comma √ 3 /4 / 5 Roll √ Curtain √ Air Knife √
Introduction Coating Methods
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Coating Methodes Spray Coater
Technical Properties – No backing roll – No kiss coat – Only applicable for low viscosity media
Operation always without backup roll limits application no edge free coating is possible
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Coating Methodes Reverse Gravure (Anilox) & Kiss Coat
Coating surface depends on – Rheology of coating media – Web tension – Wrap angle – Control of contact area
For double side coating: Kiss coat surface is not as good as gravure roll coating with backing roll
Solutions for better contact available
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Direct
Indirect
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Coating Methodes Reverse Gravure (Anilox) & Backing Roll
Backing roll improves coating surface improving coating results
For almost all coatings, because – Contact area mechanical adjusted – Not depending on web tension
Coating surface depends on – Rheology of coating media
For double side coating: Application with and without backing roll. 1st coating unit with, 2nd without Backing roll possible
Imperfect coating surface
Improved coating surface
Direct
Indirect
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Double Side Coating Possible Solutions
Almost not applicable (2x Direct gravure Coating)
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Almost not applicable (2x Indirect gravure Coating)
– Both transfer rolls are running synchronous
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What combinations of possible coating methodes are applicable ?
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Double Side Coating Possible Solutions
Applicable (2 x kiss coat indirect ) – Adjustable contact area – Adjustable web tension – Coating quality according to
kiss coat conditions
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Applicable (2 x kiss coat direct ) – Adjustable contact area – Adjustable web tenson – Coating quality according to
kiss coat conditions – Optical inspection of web not
easy – Coating fluid supply above
web
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Double Side Coating Possible Soultions
Applicable (2 x kiss coat direct ) – Adjustable contact area – Adjustable web tension – Coating quality according to
kiss coat conditions
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Applicable (2 x kiss coat direct with Mayerbar)
– All kiss coat (kiss coat direct, indirect or fountain die) applications are applicable with Mayerbar
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Double Side Coating Possible Solutions
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Applicable (Kiss coat with backing roll & kiss coat direct )
– Adjustable contact area – Adjustable web tension – Coating quality according to
backing roll conditions (1. coating) and kiss coat conditions (2. coating)
– Coating fluid supply in top of web
Applicable (Kiss coat with backing roll & kiss coat direct )
– Adjustable contact area – Adjustable web tension – Coating quality according to
backing roll conditions (1. coating) and kiss coat conditions (2. coating)
– Coating fluid supply above web
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Double Side Coating Construction for double Kiss Coat
Coating
Substrate flow direction
Coating
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Double Side Coating Construction for Fountain Die
Coating
Substrate flow direction
Coating
Available systems with spray, Mayerbar and fountain die combinations
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Double Side Coating Conclusion
Typical applications are primer, top coat, PVDC or Lacquering, resulting in higer viscosity range for coating media up to 100 mPa s
One functional (gravure & backing roll) and one primer or silicone (kiss) coating applicable
Double side coating with kiss coat is applicable Technical solutions for higher accuracy of kiss coat available on demand Coating fluids with solid contend higher than 30% are difficult
The inline coater allows enhancement to the film between the MDO and TDO just before cross stretching.
Most technical relevant application are direct gravure & kiss coat, Meyerbar with kiss, roller or fountain die coating, because coating accuracy is sufficient (no functional coating). Coating media viscosity range similar to water ~ 1 mPa s
Coating weight is dominated by streching factor, very thin coatings possible
Inline Coating Film streching
Offline Coating
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The coating result is a function of contact area, time (web speed) and coating media rheology. Contact area is a direct function of web angles and web tension.
The web tension inside the dryer is a result of the adjusted web tension for the coating process. It is not possible to seperate the web tension of coater and dryer
The dryer has to fullfill – Wide operating window (air speed and web tension) – Perfect web stability due to no lateral return air flows in the entire dryer – Perfectly even air and temperature distribution
Dryers Requirements
Right Solution are Air Floatation Dryer
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Dryer 1a Dryer 2a
Dryer 1b Dryer 2b
Single Side Coating Line Thermal Management
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Unwinder
Primer 1/2
Dryer 1
Coating 1/2
Dryer 2
Rewinder
Double Side Coating Line System Layout for Barrier Layer
Unwinder Primer 1
Dryer 1a
Coating 1
Dryer 2a Dryer 1b Dryer 2b
Primer 2 Coating 2 Rewinder
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Dryer 1 Dryer 2
Double Side Coating Line Thermal Management
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Double Side Coating Line Thermal Management: Conclusion
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Conclusion
Inline coaters are a unique solution to upgrade an existing film stretching line .
The inline coater allows enhancement to the film between the MDO and TDO just before cross stretching.
Kiss coating and backing roll coating are capable applications. Spray coatings and direct gravure coating only for special applications
All kiss coat (kiss coat direct, indirect or fountain die) applications are applicable with Mayerbar
Not capable for all functional coating applications, because only one side in backing roll quality
Inline Coating Film stretching
Offline Coating
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Conclusion
Minimization of invest cost by reducing: – Dryer length and framework – Coating units – System control software – Double Side Coater Line at 75% of single Side Coating Line
Optimization of energy consumption – Heating ~ 15% reduction – Cooling ~ 17% reduction
Costs
Technical
Reduction of web and system length Reduction of thermal stress to web Strong requirements for dryers Limitations in web tension
SAM Sungan Ralph Pagendarm
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[1] Rostásy, F.S.: Baustoffe. Verlag Kohlhammer, 1983 [2] The Rational Mechanics of Flexible or Elastic Bodies, 1638–1788: Introduction to Leonhardi Euleri
Opera Omnia, vol. X and XI, Seriei Secundae. Orell Fussli. [3] http://www.engineeringtoolbox.com/young-modulus-d_417.html [4] M.D. Lechner, Makromolekulare Chemie, Dritte überarbeitete und erweiterte Auflage, Birkhäuser
Verlag, 2003 [5] http://findout.jihua.de/?t=22 jihua.de ••• media: screen, handheld, tv [6] http://www.hug-technik.com/inhalt/ta/bestaendigkeiten.htm [7] Saechtling Kunststoff Taschenbuch ISBN 3-446-22670-2 [8] Växjö Laminierung AB Smedjegatan 22 35246 Växjö [9] Kleine Werkstoffkunde Kunststoffe; Maurer Schallschutz; Anthoptstrasse 9 /SIG Halle 104 [10] Kunststofftabellen Bodo Carlowitz Hanser Fachbuch; Auflage: 4., völlig überarb. u. erw. A. (23.
Februar 1995)
Appendix Links and Books