Innovations in Coating Technology for Graphic Art

By :Adesh KatariyaManager- R&D, Tirupati Inks Ltdplast.adesh@gmail.com

Coating-GeneralThe adding of a clear layer

on toa Substrate (printed or unprinted)

toprotect and/or enhance the appearance of products.

Coatings is more than just a protective skin; they provide the product optical and haptic characteristics that decisively influence customers’ perceptions—and buying decisions

Functions of Coatings

Typical expectations of coatings Easy application and cost effectiveness

Environmental friendlinessUniform film formation

Non-ToxicDurability

3

Appearance Protection

Types of Coating, As per Formulation

Solvent Based Coatings Water based(Aqueous) coatings Oil Base Coatings Radiation curable Coatings ( UV / EB)

4

Types of Coating, As per Application process

Gravure Application coating Anilox( or Flexo ) Coatings Roller-coater Coatings Offset Coatings Screen Coatings

5

Types of Coating , as per end use

1. OPV( Over Print Varnishes)o Packaging o Commercial

2. Functional Coatingso Primers o HSLo Barrier Coatings

6

Environment aspect & Energy consumption of Coatings

7 Green to Red /1-5: Lesser to Higher Lighter to Dark :Minor to Major

Impact on Environmental elements

Energy

Low Lavel Ozone

Ground Water

Green-house Gas

Ink Mfg.ᶰ Application (Drying)

Liquid Coatings

Solvent Based 2 1 4 1 2

Water Based 1 2 1 1 2

Radiation Curing

Photo-Initiation 2 1 1 1 4

Electron Initiation 1 1 1 1 3

Paste Oil Based 1 1 1 1 1

Performance, Cost and Risk comparison of Coatings

8 Lighter to Dark/ 1 to 5 :Low to High

Performance Cost Risk ( Health)

Liquid InkSolvent Based 3 3 5

Water Based 2 1 1

RadiationCuring

Photo-Initiation 4 5 4

Electron Initiation 5 4 3

Paste Oil Based 1 2 2

New Trends in Aqueous Coatings

Adhesion promoting Primers for Metallized Films Primers for Pre-metallization/printing on Paper Blister coatings Barrier coatings Water Repellent coatings

9

Primers for Pre-metallization/printing on Paper

10

The consistent and fine particle size of Primer coating Covering Rough and fill porous smoothly with Single Coatingo Resulting less ink consumption in printingo Smooth, high Lusture surface of metallized paper.

Standard Paper Calendared Paper Coated Paper

Blister coating

11

Coating applied on Boardand then heat sealed with PVC Packages.

Barrier coatings for Clear high Barrier laminates

1. Barrier coatings to increase Oxygen barrier properties of BOPP2. Barrier coatings to increase Moisture and gas barrier properties of PET.

12

Water Repellent coatings

Special aqueous coating for Water Repellency of corrugation board after coatingMain aim : To convert maximum wooden/plastic packing into recyclable corrugation packing.

Coated Un-coated

13

New Trends in Solvent BASED Coatings

Two-pack coatings for ghee and oil packing Scratch Resistant OPV ( 2K PU/H)for flexible

Packaging Release Coating Heat Seal coating for lidding Matt Coating for Flexible packaging

14

Two-pack coatings for ghee and oil packing

Ordinary Coating will removed by the action of Ghee / Oils but two –pack coatings are resistant to Ghee and Oils.

Increasing demand of flexible packaged Ghee .

15

Matt Coating for Flexible packaging:

Bright future Food processors are replacing glossy packages with

dull matt packages to show their product oil free , so they are replacing glossy finish into matt surface by applying matt OPV.

For sophisticated look of snacks packages

16

Heat Seal coating for lidding

Heat-seal coatings provide a bond between the plastic blister and the printed lidding material.

Mainly using for Dairy product /water packing.

17

New Trends in Energy Curable Coatings

Special effect UV Coatings1. Texture coating2. Haptic(Soft feel) coatings3. Sand effect coatings4. Glitter effect coatings5. Emboss Coatings6. Spot UV Coatings7. Sparkles UV Coating8. Thermochromic UV Coatings9. Photo-luminescent Coatings10.Pearl Effect UV Coatings11.Wrinkle coatings

18

1(A) Texture coatings: Orange Peel effect coatings

Special Screen UV Coating cured to a textured finish that looks like orange skin

19

1(B) Texture coatings: Drip Off-effects

Drip Off represents an efficient and eye-catching method to achieve matt/gloss effects . This technique gives certain areas rough and certain areas as glossy.

This is very much used in cosmetics and gives the product a luxury feel.

Duct to Anilox and Duct to duct process

20

2. UV Haptic (Soft-touch) coatings

21

This effect imparts a leather-like, almost "velvety" feel with a rich matte appearance to specific areas on an image or text

Screen , Roller coater or Anilox process used.

3 (A) SANDY FEEL COATINGS UV coating that provides a sandpaper feel upon printing

over multiple types of ink on paper or paperboard substrates via an Anilox coater or screen.

Sand paper appearance after printing

22

3(B ) Satin Sandy UV Coating

Mostly used as spot coating through screen It gives rough sand like appearance to select areas to

give a natural effect.

23

4.Glitter effect coatings:

Screen UV Coating contains small holographic bits of glitter .

The effect is most pronounced over dark colors.

24

5 Raised coatings

Raised UV Coating applied with a special roller under high pressure to form a three-dimensional impression that allows you to literally feel the design.

Heavy pattern of raised UV Coating, exhibit a unique dimensional profile.

25

Applications of Raised UV This dramatic appearance can bring to live snow on a

mountainside, raindrops on a window, the leather of a jacket and other effects also.

Above picture has a screen printed spot raised-image UV coating on the trees and leaves.26

6.Spot UV Coating

Screen gloss coating on a matt BOPP laminated prints. Only selected areas can be given a high glossy or Matt

effect on an image or text.

27

7. Sparkle UV Coating

Special screen UV Coatings contains sparkle glass flake pigments to impart the 3-d dramatic visual effect .

Unlike other glitter applications, these flakes are totally embedded and won't rub off.

28

8. Thermochromic UV Coatings

UV Screen coating ,changes colors with temperature. Prizes, offers, and messages printed with this coatings

,can be revealed only when over-rubbed, The heat fromthe friction caused by rubbing causes the coating tochange colors.

Beer producers have used this technology to indicatewhen their product is chilled.

Thermochromic coatings typically are available in variouscolors and temperature ranges (4o C and 37o C).

29

Same coating looksAt 15 DC At 40 DC

White Orange

9. Photo-luminescent (Glow-In-The-Dark) UV Coatings

These screen coatings exhibit phosphorescence (bright glowing) effect.

Coating absorb sunlight during the day and release it as light overnight

These coatings can be applied using flexo, screen, or roll coater.

30

Starpath coating ( Glow in Dark)Forget streetlights, use glow-in-the-dark, Slip and rain-resistant UV coating on

pavements illuminates paths and roads First Starpath coating is being trialled on a road in Christ's Pieces in Cambridge It has three layers, with the middle one is glow in dark UV Coating. Starpath reacts to varying levels of light. If the sky is lighter, such as on the left, it

won’t release as much luminosity. At night (right) it glows brighter.

http://www.dailymail.co.uk/

31

10. Pearlescent UV Coatings Pearl additives are mixed with gloss UV coating to give this

coating a luxurious appearance.

32

11. Wrinkle effect UV Coating

33

This special UV Coating is working with duel cure mechanism.

In first curing pass, some hyper-branched monomers cross-linked and create residual stress . After final curing wrinkle effect developed.

New Trends in Energy Curable Coatings

34

Special Application UV Coatings1. UV Coating for PVC Profiles2. Optical Fiber UV Coatings3. Anti-fog UV coating4. Release Coatings5. Hot Foil Stampable UV Coatings6. Holographic UV coating7. UV LED Curable coatings8. EB Curable coatings

1. UV Coating for PVC Profiles

UV coating is applied to the surface of the product that filters out UV spectral light from the sun which would otherwise degrade the PVC more quickly.

Versatile applications areo PVC door/window profileo Ceiling panel/wall panelo Matt /glossy laminate etc.

35

2. Optical Fiber UV Coatings

Optical fibers are so designed that their transmission properties will notchange despite fluctuations in the temperature and humidity of theirenvironment or the passage of time, and in this requirement can befulfill by extrusion lamination or UV Coating.

The most generally used fibers are silica- based, and they have superior transmission characteristics, but silica glass is easily fractured by external forces.

The fibers are therefore covered with two layers of coating to protect it and compensate for its mechanical strength.

36

3. Release UV Coating

Widely used in Label industry Silicone chemistry. UV curable release coating does

not affect the bond-strength of Label’s adhesive bond strength.

37

5. water-resistant anti-fog UV coating on plastic materialA combined hydrophilic and Hydrophobic , anti-fog coating film are prepared for manufacturing a hard, water-resistant anti-fog UV coating.Mechanism of working: Till now, three mechanism used :either Reduce or Increase the water contact angle or Increasing the water absorption by water-absorbing polymer. But new technique is based on combination of hydrophilic(Increase the water contact angle) and Hydrophobic (reduce the water contact angle) mechanism.

38

.Applicationso Commercial complexes outer bodyo Safety Glasses or Visorso Electronics Protection Coverso Advertisement Signageo Storefront Windows/Doors

Desired Featureso Permanent Anti-Fog Coating Treatment for Plastic Substrateso Washable Coating ( Good detergent/Acid rain Resistance)o Good Scratch and Impact Resistanceo Simple Wet Chemical Application Methods and Fast Curing Process o Long Coating Solution Shelf Life with Stable Chemical and Physical Properties

39

6. Holographic UV coating: Cast & Cure

This technique creates a clear holographic pattern over all types of printed materials.

The process utilizes a specialty film with micro-embossed patterns. Once the UV coating is applied, the film is placed over the top of the

coating and then cured. After curing, the film is stripped away, leaving a holographic effect on the sheet or web.

40

7. UV LED COATINGS

Special Coatings , designed as per UV LED Lamps emission spectrum.

UV LED curing systems generate exclusively monochromatic light, which means that only a small wave window is available.

Major UV LED Lamp’s available in 365 NM, 385NM and 395 nm range of UV Spectrum.

41

UV-LED advantages

No IR radiation and minimal heat transfer to the substrate

LED’s operate on low voltages making them electrically simpler and safer

No shutters – instant on /off Matrix design enables easy application configuration Consistent UV output over the operating life UV-LED‘s offer uniform radiation across the exposure

width

42

8. Nail-gel UV LED Coatings

43

UV LED Curable Nail gels coating with textured glass flakes

9. Electron beam (EB) Coatings

X-ray system (electrons instead of photons) Electrons can break the chemical bonds (ionizing radiation) -no

photo-initiators are needed

44

.EB –Advantages Lower cost by replacing film laminated flexible packing with surface printed and

coated mono-web packaging High gloss appearance High heat, mechanical, and chemical resistance of cured EB coating EB is not much affected by pigments

Challenge Matching appearance and handling of reverse printed laminated packaging Odor, taint, food law compliance Functional properties (COF, weatherability, ink protection) Patent covering film food packaging applications (Cryovac US 6,528,127) Interstation curing very difficult . Very high cost of Machine. Higher energy transport (total energy curing energy-comparable)

45

EB Coating User Requests

Lower capital costs Improved reliability Lower cost of operation Easy and inexpensive maintenance Wider ranges of voltages Customization for new applications Lager range of web widths Non-web product handling

46

Other Applications of UV/EB technology in industry:

Automotive Industry: UV coatings on Light Reflectors, seat frames, wiper frames, diesel engine pumps.

Protective Industry: Temporary storage UV primer for steel pipes, Protective and aesthetic topcoat for ind.pipes

Coil Coating Industry: UV topcoat for household appliance and UV primer and UV or EB topcoat for construction steel and aluminum

Can Coating Industry: UV Base Rim Coats, UV protective topcoat

Consumer Electronics: UV topcoat on mobile phone housing

47

Coating Market in Asia-Pacific Region:

China accounts for 58% of the region’s consumption in volume and 55% of the value.

India is now the second-largest consumer in tons, with a 13% share, and is third in value, with 10%.

Japan is second in value, comprising 12% of the total, but is expected to be displaced by India within the next two years.

Korea is the fourth-largest consumer in both volume and value. These four countries took 84% of the region’s tons and 85% of the

value. Indonesia, Thailand and Vietnam each consumes about 2-3% of the

regional volume and are considered expanding markets. Australia, Taiwan and Singapore are mature outlets for coatings

Sourse: Kusumgar, Nerlfi & Growney’s study

48

Future Developments

Commercially suitable UV-LED Coatings. Low cost and changeable EB Lamps Energy reflectable UV Coatings for outdoor

windows/Panels UV LED Coatings in Textiles Heat seal/barrier coatings for direct food contact Biodegradable coatings for PLA Films

49

Few Points In general the trend is for coatings to become

increasingly more sophisticated in order to meet the packaging, commercial and advertising world’s

need for better visual image.

Future demand drivershall beQuality

50

THANK YOU