Structural Analysis and Design of Foundations: A Comprehensive Handbook for S...
New Era Converting Machinery – Gravure Coating Webinar
1. Gravure Coating:
Webinar – April 26, 2012
John Looser
New Era Converting Machinery
P.O. Box 377
Hawthorne, NJ 07506
Phone: 973-413-4605
E-mail: john.looser@neweraconverting.comwww.neweraconverting.com
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One of the Most Versatile Methods in the Industry
3. Classic Gravure Coater
• Sections:
– Coating Reservoir (Pan)
– Gravure Roll (Etched Metal)
– Doctor Blade
– Impression Roll (Rubber)
• Process:
– Coating Pick-up
• Fill Cells
– Wipe (Doctor) Excess
– Transfer Coating
• “Empty” Cells (Transfer Efficiency)
• Film Split
Impression /
Back-up Roll
Gravure
Roll
Doctor
Blade
Coating Pan
Coated
Web
Incoming
Web
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4. Classic Gravure Coater
Impression /
Back-up Roll
Gravure
Roll
Doctor
Blade
Coating Pan
Coated
Web
Incoming
Web
4
• Terminology:
– Direct Gravure
– Forward Application
• Synchronous Rotation
– Pan Fed
5. Classic Gravure Coater
• Coating Reservoir
– Enclosed Applicator Shown
• Gravure Roll
– Motor Driven
– Pneumatically Positioned
• Doctor Blade
– Integral to Enclosed Applicator
• Impression Roll
– Nip/Web Driven
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6. Coating Pan
• Function: Delivers Coating to Gravure Roll
• Maintain Constant Level
– Stand Pipe or Overflow Weir
• Consistent Coating Movement
– Continuous Recirculation
– Foam Management
– Avoid Solids Settling
• Enclosure / Covers
– Minimize Solvent Evaporation
– Contain Slinging
• Pneumatic Pan Lift
Gravure
Roll
Doctor
Blade
Supply
ReturnReturn
Gravure
Roll
Doctor
Blade
Supply Return
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7. Gravure Roll
• Function: Deliver Consistent Coating
– Homogeneous Transfer (Across and Down Web)
• Etched / Patterned Cylinder
– Determines Coat Weight and Appearance
– Cell Creation: Mechanical / Laser / Electronic
• Driven Roll
– Tension Control
– Idle Mode
– Vector or Servo Controlled
• Cored for Temperature Control
– Heat Management
– Viscosity Control
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8. Cell Creation – Gravure Patterns
• Cell - Coating Reservoir
– 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
– Patterns / Shapes
• Appearance and Flow
• Promote Release
• Methods for Cell Creation
– Mechanical Engraving
– Laser Engraving
– Electronic Engraving
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9. Cell Creation – Mechanical Engraving
• Roll Design
– Steel Core with Soft Copper Layer
– Chrome Plating Over Pattern
• Cell Creation
– Patterned Tooling Stamps/Forms
Shapes
– Material is NOT Removed
• Surface is Re-Formed
– Roll Precision Can Be Affected
• Release Characteristics
– Most Angles are 45o
– High Surface Tension
– Average Release 40-50%
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15. Doctor Blade
• Function: Remove Excess Coating
– Coating in Cells Only
– Cell Determines Coat Weight
• Angle of Attack
– Trailing Blade
• Low Speed / Low Viscosity
• Hydraulic Forces Can Lift Blade
• Traps Contaminates
– Reverse Angle / Chisel / Plowing
• Increased Speed and Viscosity
• Hydraulic Force Helps Hold Blade
• Rejects Contaminates
• Loading Pressure
– 0.5 – 4.0 pli
Gravure
Roll
Coating Pan
Trailing Blade
25-30o
Gravure
Roll
Coating Pan
Reverse Angle
30o
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16. Doctor Blade
• Materials
– High Carbon Spring Steel
– Stainless Steel
– Mylar
– UHMW
– …………
• Different Shapes
– Most Common = Simple Bevel
17. • Pneumatically Loaded
– On/Off Control
• Angle Adjustment
– Coarse: Trailing and Reverse
– Fine: Attack Angle
• Oscillation
– Motor Driven
Typical Blade Holder
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18. Impression Roll
• Supports Substrate
– Rubber Covered Roll
– 65-90 Shore A Durometer
• Nip Footprint
– Impression: 0.25” – 0.375”
• Controls Coating Width
– Undercut Roll
– Lift Edges Off Gravure Roll
– Unique Roll for Each Web Width
Web
Gravure Roll
Impression Roll
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19. Impression Roll
• Impact on Coating Quantity and Quality
– Roll Durometer Impacts Amount of Coating Transferred
• Thick Soft Covering (60-70 duro) = Large Footprint = More Coating
• Thin Hard Covering (80-90 duro) = Small Footprint = Less Coating
– Higher Precision Leads to Better Coating Uniformity
• Soft Roll = .002 - .004” TIR
• Hard Roll = .0005” - .001 TIR
– Thin Precision Coating
• Hard Cover – Small Footprint – Precision Roll
20. Impression Control
• Pressure Only
– Pressure in Loading Cylinders Set
Impression
– No Position Stops Between Rolls
– Difficult to Control
• Cylinders Lift Roll / Pan / Motor AND Sets
Impression
• Pressure Changes Impact Impression
• Adjustable Stops
– Cylinders are Utilized for Positioning
– Stop Setting Dictates Impression
– High Loading Pressure = Stability
– Fine / Repeatable Adjustment
• Stop Configurations
– Coarse Thread
– Differential Screw
– Taper Wedge Block 20
22. Enclosed Applicator
Supply
Impression /
Back-up Roll
Coated
Web
Incoming
Web
Return
• Enclosed System
– No Slinging of Coating
– Minimizes Solvent Evaporation
– Reduced System Volume
• High Rate of Recirculation
– Minimizes Air Entrapment
– Foam Control – Flows Out of
Chamber
• Easy to Clean
– Simple Flushing Systems
– Minimize Waste
Gravure
Roll
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24. Impression Roll: Sleeve System
• Impression Roll:
– Rubber Covered Sleeve
– Steel Mandrel
• Drive Side
– Cantilever Support
• Operator Side
– Removable Bearing Support
• Quick Width Change
– 5 Minute Task
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25. Impression Roll: Sleeve System
• Air Pressure Expands Sleeve
– Floats Off Mandrel
• Straight or Tapered Mandrel
• Sleeves
– Nickel
– Composite
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26. Cartridge System
• Base Frame and Drive Stand
Fixed in Web Line
• Gravure Roll, Impression Roll
and Coating Applicator on
Cartridge
• Quick Change System
– Off-Line Clean-up
– Coating Change
– 10 Minute Change-out Time
• Typical Features
– Precision Rails Maintain
Alignment
– Quick Connects for Air and
Electrical
– Tool-less Quick Disconnect Drive
Coupling 26
27. Cartridge System
• Base Frame with Applicator Roll,
Impression Roll and Drive Stand
Fixed in Web Line
• Gravure Cartridge Installed
• Five Motors on Drive Stand
• 5-Roll Transfer Coating
– Two Rolls on Base
– Three Rolls on Cartridge
• Quick Change System
– Switch Between Methods
– Clean-up Off-Line
– 10 Minute Change-out Time
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29. Reverse Gravure
• Reverse Application
– Speed Range: 90-120%
• Benefits
– Removes Cell Pattern
– Film Split Avoided
• Minimizes Ribbing
– Adjust Coat Weight with Roll
Speed
• Impression Control is Critical
– Light / Controlled Impression
– Precision Required – Better Rolls
• Driven Impression Roll
– Suggested for Tension Control
– Overcome Reverse Action
Impression /
Back-up Roll
Gravure
Roll
Doctor
Blade
Coating Pan
Coated
Web
Incoming
Web
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30. Offset Gravure
• 3-Roll System
– Gravure is Offset from Substrate
– Removes Substrate from Coating Nip
• Protects Sensitive Substrates
• Roll Rotation
– All Roll Same Direction
• Synchronous Rotation
– Two Film Splits
– Thinner Coatings
• Roll Speeds
– All Rolls at 100% Line Speed
– Single Drive is Possible
• Gravure Roll is Typically Driven – Idle Mode
• Applicator Roll is Nip Driven
• Back-up Roll is Web Driven
Steel
Back-up Roll
Gravure
“Forward”
Doctor
Blade
Coating Pan
Coated
Web
Incoming
Web
Rubber
Applicator Roll
“Forward”
Film
Split
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Film
Split
31. Differential Offset Gravure
• 3-Roll System
• Roll Rotation
– Gravure: Forward / Reverse
– Applicator: Forward / Reverse
• Roll Speeds
– Gravure: Variable
– Applicator: Variable
– Back-Up: Controls Tension
– All Rolls are Driven
• Roll Function
– Gravure: Coat Weight Control
– Applicator: Appearance Control
Doctor
Blade
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Steel
Back-up Roll
Gravure
Fwd / Rev
Coating Pan
Coated
Web
Incoming
Web
Rubber
Applicator Roll
Fwd / Rev
Film
Split
Film
Split
32. Differential Offset Gravure
• Cartridge Coater
• All Driven Rolls
– Additional Drives for 5- Roll Coating
• Wide Range of Set-ups
– Gloss Top Coat
• Gravure = 100%, Applicator = 100%
– Silicone Coating
• Gravure = 5%, Applicator = 95%
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33. Process Handles: 2-Roll Gravure
Coat Weight and Appearance
• Direct Gravure - Forward Application
1. Gravure Roll Selection
2. Gravure / Back-up Roll Nip Footprint
• Direct Gravure – Reverse Application
1. Gravure Roll Selection
2. Gravure / Back-up Roll Nip Footprint
3. Gravure Roll Direction
4. Gravure Roll Speed
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34. Process Handles: 3-Roll Gravure
Coat Weight and Appearance
• Offset Gravure
1. Gravure Roll Selection
2. Gravure / Applicator Roll Nip Footprint
3. Applicator / Back-up Roll Nip Footprint
• Differential Offset Gravure
1. Gravure Roll Selection
2. Gravure / Back-up Roll Nip Footprint
3. Applicator / Back-up Roll Nip Footprint
4. Gravure Roll Direction
5. Gravure Roll Speed
6. Applicator Roll Direction
7. Applicator Roll Speed
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37. Pressurized Coating Applicator
Pressurized
Applicator
• Adjustable Coat Weight with a Single Cylinder
– 50-100% Weight Increase
– Reduced Gravure Roll Inventory
• Extended Coat Weight Range
– Thicker Coatings
• Constant Coat Weight with Increasing Speed
– More Efficient in Filling Gravure Cells
– Less Recirculation and Foam Generation
• Higher Viscosity and % Solids
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38. Simultaneous Two-Side Coating
Gravure
Roll
Gravure
Roll
• 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
39. Two-Side Coating
• Offset “Kiss” Coat
– Unsupported
Applicator
Roll
Gravure
Roll
Gravure
Roll
Applicator
Roll
• Offset Coat
– Supported
Applicator
Roll
Applicator
Roll
Gravure
Roll
Gravure
Roll
40. Versatility
• Application Range
– Speeds: 0 - 2000+ fpm
– Widths: 0 - 200+ inches
• Substrates:
– Papers
– Boards
– Films
– Foils
– Wovens / Non-wovens
– ………
• Coating Types:
– Water Based
– Solvent Based
– 100% Solids (UV and E-Beam Cure)
– Hot Melt: Adhesives and Waxes
– ………
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41. Versatility
• Viscosity and Wet Coating Thickness:
– 2-Roll Gravure:
• 10-1000 cps
• 0.0005” – 0.0015”
– 3-Roll Gravure
• 50 – 2000 cps
• 0.0001” – 0.001”
– Pressurized Gravure
• 100 – 5000 cps
• 0.0005” – 0.005”
• Coatings:
– PSA’s: Solvent, Aqueous and Hot Melt
– PVDC and other Barrier Coatings
– Primer Coats
– Topcoats: High Gloss and Protective
– Laminating Adhesives
– Silicones: Solvent, Aqueous, 100% Solids
– ……….. 41
42. 42
• Top Coats for Wear Resistance on
Magazines
• Gloss / Color Snap Coatings for
Automotive Brochures
• Adhesives for Wood Grain Patterned
Coverings on Furniture
• Gas Emissive Coatings for Medical
Packaging
• Protective Coatings on Appliance
Overlay
• Optically Clear Adhesives for
Protective Window Films
• Silicone Based Release Liners for
Medical Bandages
• Pressure Sensitive Adhesives for
Medical Bandages
Versatility
• Lamination Adhesives for Medical
Drapery
• Primer Coatings for Aluminum Layer
in Cigarette Packaging
• Optically Clear Adhesives for Bottle
Labels
• Adhesives on Masking Films
• Reactive Coatings on Thermal
Papers
• Pre-Paste on Wall Coverings
• Tinting of Decorative Fabrics
• Laminating Adhesives for Lottery
Tickets
• Bonding Layer for Foam / Fabric
Headliners
43. Questions?
Thank You!
Graphic References
• Doctor Blades
– Benton Graphics
• Gravure Roll Slides:
– Zecher
– Pamarco
• Enclosed Applicator
– Harris and Bruno
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John Looser
New Era Converting Machinery
P.O. Box 377
Hawthorne, NJ 07506
Phone: 973-413-4605
E-mail: john.looser@neweraconverting.comwww.neweraconverting.com