Professional Documents
Culture Documents
3 Coating
3 Coating
Lee A. Ostness
fresh red meat, bulk liquids, cereals, cake mix, coffee, medical device
films, snacks and many others.
see chart
COATINGS
PET
1 10 mil
Primers
PE
1 8 mil
Adhesives
Al Foil
20 60
PVDC
BOPP/OPP
0.4 2 mil
Wash-coats
CPP
1 4 mil
PVOH
0.5 gsm
Nylon
0.4 2 mil
Lacquers
5.0 gsm
MetPET
1 10 mil
Varnishes
Cellophane
0.8 1 mil
Acrylic Polyurethanes
0.3 gsm
The beverage
12.6
(PRINT)
PET
12.6
(PRINT)
PRIMER
0.04
LDPE
12.6
FOIL
FOIL
6.3
Beverage Package
PRIMER
LDPE
6.3
0.04
25
Retort Package
The
The
To select the coater for your needs you first need to know
your coating and substrates properties, then match these properties with
the coaters abilities/limitations.
Coating
Substrate
Coater
% Solids
Absorbency
Speed Range
Viscosity
Surface Tension
pH
Tear Strength
Solids Range
Shear Stability
Smoothness
Viscosity Range
Density
Caliper
Appearance
Solvent/Water Based
Melt Point
There are four main coater configurations used in the Flex Package
construction. The four types are Direct Gravure, Reverse Gravure, Offset
Gravure and Smooth Roll.
The
This pattern
Direct
Gravure
Reverse
Gravure
Offset
Gravure
Smooth
Roll
coating from an open pan, picking up the coating with a smooth steel roll
partially immersed into the pan, then the web is pressed against the steel
roll with the rubber covered back-up roll. The speed of the steel roll and
amount of pressure against the steel roll combine to control the amount
of coating applied to the web.
The gravure roll is a steel roll with a precise pattern engraved into the
surface of the roll. There are several gravure vendors, each with their
own names for these patterns. The picture shows one vendors patterns
and the names associated
with them. The patterns
are called from left to
The amount
solids column that matches your formulation. Then follow the row to the
left and it determines the volume required to deliver the desired coating
to the substrate.
This chart is setup for the Direct Gravure method. The Reverse Gravure
method will need to add approximately 20% to the desired coat weight
and for Offset Gravure method add approximately 75%.
This will be
The chart is only a starting point to get you close to your target. A large
amount of the time the gravure pattern will need to be adjusted to
achieve the correct coat weight due to the different coating and/or
substrate characteristics.
Direct Gravure Coater:
The Direct Gravure Coater consists of a rubber
covered back-up roll, a gravure roll, and a coating
applicator. The back-up roll is covered with a rubber
against the gravure roll creating a slight nip which pulls the coating out
of the gravure cells and deposits the coating onto the web. The gravure
roll is a steel roll with a pattern engraved into the face of the roll. These
cells are filled with the coating and doctored of the surface of the roll
leaving a precise amount of coating on the gravure roll. The roll then
transports the coating to the nip where it is transferred to the web. The
coating applicator is either an enclosed chamber with two doctor blades
or an open pan with a doctor blade assembly to remove the excess
coating.
GSM
95%
100%
105%
Gravure Speed
speed.
In this
gravure methods.
100%
150%
60%
100%
The coat
Gravure Speed weight usually levels off when the gravure roll reaches
differential speeds and the two nip points generally apply a smooth
coating.
The Smooth Roll Coater consist of a rubber covered backup roll, a steel chrome plated pick-up roll, sling guards
and a coating pan.
immersed into the coating pan and transports the coating to the nip
between the web and the pick-up roll. The coating is applied to the web
and the nip force. The coating pan is filled with a solution coating and in
most cases it has an overflow weir so the coating may be recirculated.
With this
method the coat weight increases with higher speed and higher viscosity.
The surface tension is selected based on the compound of the rubber.
This method requires the rubber to repel the coating, so only the web will
be coated. The resilience and tear strength are required due to the high
forces and different web widths. The coat weight is determined by the nip
width and the pick-up roll speed and the curve will be a line
GSM
10%
100%
Pick-up Speed
generated.
transferred at the width of the web. If the rubber is not undercut the
coating would form a flooded nip outside the area of the web and
gradually move into the web area, creating a hydraulic force that would
increase the coat weight to unacceptable levels in these areas.
If the
rubber was undercut, the area outside the width of the web would
continue to travel around and back into the coating applicator.
The
smooth roll coater requires a full width rubber roll to create the flooded
nip. If the nip was not flooded across the entire web, some areas would
have either too little coating or none at all. This flooded nip also requires
sling guards at the end of the rolls to catch and return into the pan any of
the slinging coating.
A nip is required between the coating rolls in all of the methods listed
above. What is a nip? A nip is the amount of contact that is generated
between the rolls when they are pressed together. The softer the rubber
durometer, the wider the nip will be with the same pressure.
As the
pressure increases the nip width increases. How do you measure the nip
width?
IMPRESSION
PAPER
RUBBER
COVERED
ROLL
TORQUE SHAFT
SHOULD BE
LEVELED
In review, the coat weight control of each coater as depicted in the charts
show that the only coater that cannot adjust coat weight is the Direct
Gravure (shown as forward gravure in the illustration).
Reverse
Gravure
Forward
Gravure
Offset
Gravure
Smooth
Transfer
100%
150%
GSM
50%
Gravure Speed
GSM
GSM
GSM
95%
100%
105%
Gravure Speed
10%
60%
100%
Gravure Speed
10%
100%
Pick-up Speed
The smooth roll coater can control coat weight until the hydraulic force
over comes the coater nip and then the coat weight climbs dramatically.
The Gravure coaters offer excellent coat weight control and are stable
through out all line speeds but require an undercut rubber roll for each
web width. A sleeve system may be used in the rubber roll location. The
the line speed increases so does the amount of coating supplied. The
result is much of the coated web during speed-up and slow down is
waste. The advantage to the smooth roll coater is it only requires one
rubber roll for all web widths.
Gravure
GSM
Smooth Roll
Line Speed
The Direct Gravure coater is used primarily on substrates that are fragile,
like metalized PET or printed webs. If the roll applying the coating to
these two examples were operated in the reverse direction or at a
differential speed, then that roll could damage the print layer or pick off
the foil. Operating the roll in the forward direction with matched speeds
will apply the coating without damage. The smooth roll coater can adjust
coat weights and apply coatings without damage to the layers. The limit
on this coater is the flooded nip. This application works well on films or
coated papers, BUT on open face paper the coat weight cannot be
controlled. Passing the open faced paper through the flooded nip will
saturate the web and apply excessive coating.
Take all the parameters from this paper and create a chart, now you can
select the correct coater for your process.
Direct
Reverse
Offset
Smooth
Gravure
Gravure
Gravure
Roll
No
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
No
Yes
Yes
Coater Selection
2006 PLACE
Conference
September 17-21
Cincinnati, Ohio
Coating Technology
for Flexible Packaging
Presented by:
Lee A. Ostness
Product Manager Coating & Drying Systems
Black Clawson Converting Machinery
Typical Products
Product
Processed Meat
Processed Cheese
Fresh Red Meat
Bulk Liquids
Cereal/Cake Mix
Medical Devices Films
Coffee
Fresh Produce
Snacks
Package Type
Pouches, Vacuum Packages
Pouches, Wraps
Barrier, Shrink Bags
Pouches, Bag in Box
Inner Liners
Pouches, Thermal Formed
Brick Packs, Pouches
Breathable Bags
Bags
Flex-Pack Components
Substrates
PET
PE
Al foil
BOPP/OPP
CPP
Nylon
METPET
Cellophane
Coatings
1-10 mil
1-8 mil
20-60
0.4-2 mil
1-4 mil
0.4-2 mil
1-10 mil
0.8-1 mil
Primers
0.04-0.4 gsm
Adhesives
3.25-6.5 gsm
PVDC
1.6-6.5 gsm
Wash-coats
0.8-1.5 gsm
PVOH
0.5 gsm
Lacquer
5.0 gsm
Acrylic Polyurethane
0.3 gsm
Varnish
0.02 0.04 gsm
12.6
(PRINT)
PET
12.6
(PRINT)
PRIMER
0.04
LDPE
12.6
FOIL
FOIL
6.3
Beverage Package
PRIMER
LDPE
6.3
0.04
25
Retort Package
Note: The foil is a barrier layer and may be substituted with METPET, Nylon, or EVOH
depending on the amount or type of barrier layer needed.
COATER/DRYER
Coater
Smooth roll
Backing Roll not Undercut
Pan Fed
Direct Gravure
Backing Roll Undercut
Sleeve
Pan Fed
Enclosed Applicator
Dryer
Air Floatation Nozzles
Roll Support
FLEX-PACK COATERS
Direct
Gravure
Reverse
Gravure
Offset
Gravure
Smooth
Roll
Methodology of Application
Gravure Coater
Volume
BCM
Billion Cubic Microns
The formula is based on
ink technology. Many of
today's coatings are of
an unique composition.
Use this formula for a
better understanding of
how the cell volumes are
achieved. Coat weights
may vary when different
coatings are applied with
the same cell volume.
CELL
DEPTH
0.0008
0.0009
0.0010
0.0020
0.0022
0.0025
0.0030
0.0032
0.0033
0.0035
0.0038
0.0040
0.0045
0.0050
0.0058
0.0062
0.0076
0.0090
0.0104
VOLUME
2.6
3.2
3.4
7.5
8.2
9.7
11.0
11.9
12.2
13.9
16.0
17.3
18.0
20.4
24.4
26.6
33.7
41.0
48.0
PYRAMID CELL
15%
5%
SOLIDS SOLIDS
0.21
0.26
0.23
0.29
0.26
0.32
0.51
0.64
0.56
0.70
0.64
0.80
0.77
0.96
0.81
1.02
0.85
1.06
1.03
1.20
0.98
1.22
1.02
1.28
1.15
1.44
1.28
1.60
1.49
1.86
1.58
1.98
1.94
2.42
2.30
2.88
2.67
3.33
CHART #2
25%
SOLIDS
0.32
0.36
0.40
0.80
0.88
1.00
1.20
1.28
1.32
1.40
1.52
1.60
1.80
2.00
2.32
2.48
3.02
3.60
4.16
35%
SOLIDS
0.47
0.53
0.59
1.18
1.30
1.48
1.78
1.89
1.95
2.07
2.25
2.37
2.66
2.96
3.43
3.67
4.47
5.33
6.15
45%
SOLIDS
0.70
0.79
0.88
1.75
1.92
2.19
2.63
2.80
2.89
3.07
3.33
3.50
3.94
4.38
5.08
5.43
6.61
7.88
9.11
PYRAMID CELL
15%
5%
SOLIDS SOLIDS
0.17
0.21
0.19
0.23
0.20
0.26
0.41
0.51
0.45
0.56
0.51
0.64
0.61
0.77
0.65
0.82
0.68
0.85
0.82
0.96
0.78
0.98
0.82
1.02
0.92
1.15
1.02
1.28
1.19
1.49
1.26
1.58
1.55
1.94
1.84
2.30
2.13
2.66
25%
SOLIDS
0.26
0.29
0.32
0.64
0.70
0.80
0.96
1.02
1.06
1.12
1.22
1.28
1.44
1.60
1.86
1.98
2.42
2.88
3.33
35%
SOLIDS
0.38
0.42
0.47
0.94
1.04
1.18
1.42
1.51
1.56
1.66
1.80
1.90
2.13
2.37
2.74
2.94
3.58
4.26
4.92
45%
SOLIDS
0.56
0.63
0.70
1.40
1.54
1.75
2.10
2.24
2.31
2.46
2.66
2.80
3.15
3.50
4.06
4.34
5.29
6.30
7.29
PYRAMID CELL
15%
5%
SOLIDS SOLIDS
0.14
0.17
0.15
0.19
0.16
0.20
0.33
0.41
0.36
0.45
0.41
0.51
0.49
0.61
0.52
0.65
0.54
0.68
0.66
0.77
0.63
0.78
0.66
0.82
0.74
0.92
0.82
1.02
0.95
1.19
1.01
1.27
1.24
1.55
1.47
1.84
1.71
2.13
25%
SOLIDS
0.20
0.23
0.26
0.51
0.56
0.64
0.77
0.82
0.84
0.90
0.97
1.02
1.15
1.28
1.48
1.59
1.93
2.30
2.66
35%
SOLIDS
0.30
0.34
0.38
0.76
0.83
0.95
1.14
1.21
1.25
1.32
1.44
1.52
1.70
1.89
2.20
2.35
2.86
3.41
3.94
45%
SOLIDS
0.45
0.51
0.56
1.12
1.23
1.40
1.68
1.79
1.85
1.96
2.13
2.24
2.52
2.80
3.25
3.48
4.23
5.04
5.83
OFFSET GRAVURE
CHART #12
PYRAMID CELL
CELL
15%
5%
VOLUME
DEPTH
SOLIDS SOLIDS
0.0008
2.6
0.06
0.07
0.0009
3.2
0.06
0.08
0.0010
3.4
0.07
0.08
0.0020
7.5
0.14
0.17
0.0022
8.2
0.15
0.18
0.0025
9.7
0.17
0.21
0.0030
11.0
0.20
0.25
0.0032
11.9
0.21
0.27
0.0033
12.2
0.22
0.28
0.0035
13.9
0.27
0.32
0.0038
16.0
0.26
0.32
0.0040
17.3
0.27
0.34
0.0045
18.0
0.30
0.38
0.0050
20.4
0.34
0.42
0.0058
24.4
0.39
0.49
0.0062
26.6
0.42
0.52
0.0076
33.7
0.51
0.64
0.0090
41.0
0.61
0.76
0.0104
48.0
0.70
0.88
25%
SOLIDS
0.08
0.10
0.11
0.21
0.23
0.26
0.32
0.34
0.35
0.37
0.40
0.42
0.48
0.53
0.61
0.65
0.80
0.95
1.10
35%
SOLIDS
0.12
0.14
0.16
0.31
0.34
0.39
0.47
0.50
0.51
0.55
0.59
0.63
0.70
0.78
0.91
0.97
1.18
1.41
1.62
45%
SOLIDS
0.18
0.21
0.23
0.46
0.51
0.58
0.69
0.74
0.76
0.81
0.88
0.92
1.04
1.16
1.34
1.43
1.75
2.08
2.41
0.0008
0.0009
0.0010
0.0020
0.0022
0.0025
0.0030
0.0032
0.0033
0.0035
0.0038
0.0040
0.0045
0.0050
0.0058
0.0062
0.0076
0.0090
0.0104
2.6
3.2
3.4
7.5
8.2
9.7
11.0
11.9
12.2
13.9
16.0
17.3
18.0
20.4
24.4
26.6
33.7
41.0
48.0
2.6
3.2
3.4
7.5
8.2
9.7
11.0
11.9
12.2
13.9
16.0
17.3
18.0
20.4
24.4
26.6
33.7
41.0
48.0
NUMBER
200
190
180
165
150
140
130
120
110
96
85
75
65
55
45
35
30
25
16
CELL
DEPTH
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170
VOLUME
5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0
QUADRANGULAR CELL
15%
25%
5%
SOLIDS SOLIDS SOLIDS
0.22
0.32
0.48
0.27
0.40
0.60
0.33
0.48
0.72
0.30
0.49
0.80
0.46
0.68
1.00
0.51
0.76
1.12
0.55
0.81
1.20
0.59
0.87
1.28
0.71
1.05
1.56
0.80
1.19
1.76
0.90
1.32
1.96
0.98
1.46
2.16
1.10
1.62
2.40
1.19
1.76
2.60
1.24
1.84
2.72
1.28
1.89
2.80
1.64
2.43
3.60
2.19
3.25
4.80
3.11
4.60
6.80
CHART #3
35%
SOLIDS
0.71
0.89
1.07
1.30
1.48
1.66
1.78
1.89
2.31
2.61
2.90
3.20
3.55
3.85
4.03
4.14
5.33
7.10
10.06
45%
SOLIDS
1.05
1.31
1.58
1.93
2.19
2.45
2.63
2.80
3.42
3.85
4.29
4.73
5.26
5.69
5.96
6.13
7.88
10.51
14.89
50%
SOLIDS
1.31
1.63
1.96
2.39
2.72
3.05
3.26
3.48
4.24
4.79
5.33
5.88
6.53
7.07
7.40
7.62
9.79
13.06
16.50
35%
SOLIDS
0.57
0.71
0.86
1.04
1.18
1.33
1.42
1.51
1.85
2.09
2.32
2.56
2.84
3.08
3.22
3.31
4.26
5.68
8.05
45%
SOLIDS
0.84
1.05
1.26
1.54
1.75
1.96
2.10
2.24
2.74
3.08
3.43
3.78
4.21
4.55
4.77
4.90
6.30
8.41
11.91
50%
SOLIDS
1.05
1.30
1.57
1.91
2.18
2.44
2.61
2.78
3.39
3.83
4.26
4.70
5.22
5.66
5.92
6.10
7.83
10.45
13.20
QUADRANGULAR CELL
15%
25%
5%
SOLIDS SOLIDS SOLIDS
0.14
0.21
0.31
0.17
0.26
0.38
0.21
0.31
0.46
0.19
0.32
0.51
0.29
0.43
0.64
0.33
0.48
0.72
0.35
0.52
0.77
0.38
0.55
0.82
0.46
0.67
1.00
0.51
0.76
1.13
0.57
0.85
1.25
0.63
0.93
1.38
0.70
1.04
1.54
0.76
1.12
1.66
0.79
1.17
1.74
0.82
1.21
1.79
1.05
1.56
2.30
1.40
2.08
3.07
1.99
2.94
4.35
35%
SOLIDS
0.45
0.57
0.68
0.83
0.95
1.06
1.14
1.21
1.48
1.67
1.86
2.05
2.27
2.46
2.58
2.65
3.41
4.54
6.44
45%
SOLIDS
0.67
0.84
1.01
1.24
1.40
1.57
1.68
1.79
2.19
2.46
2.75
3.03
3.37
3.64
3.81
3.92
5.04
6.73
9.53
50%
SOLIDS
0.84
1.04
1.25
1.53
1.74
1.95
2.09
2.23
2.71
3.07
3.41
3.76
4.18
4.52
4.74
4.88
6.27
8.36
10.56
OFFSET GRAVURE
CHART #13
QUADRANGULAR CELL
CELL
15%
25%
5%
VOLUME
DEPTH
SOLIDS SOLIDS SOLIDS
0.0012
5.7
0.06
0.09
0.13
0.0015
7.5
0.07
0.11
0.16
0.0018
9.4
0.09
0.13
0.19
0.0022
10.9
0.08
0.13
0.21
0.0025
13.3
0.12
0.18
0.26
0.0028
15.0
0.13
0.20
0.30
0.0030
16.0
0.14
0.21
0.32
0.0032
17.2
0.15
0.23
0.34
0.0039
21.4
0.19
0.28
0.41
0.0044
26.3
0.21
0.31
0.46
0.0049
30.0
0.24
0.35
0.52
0.0054
32.0
0.26
0.38
0.57
0.0060
35.4
0.29
0.43
0.63
0.0065
40.4
0.31
0.46
0.69
0.0068
44.5
0.33
0.48
0.72
0.0070
46.6
0.34
0.50
0.74
0.0090
58.7
0.43
0.64
0.95
0.0120
81.0
0.58
0.86
1.27
0.0170
117.0
0.82
1.21
1.80
35%
SOLIDS
0.19
0.23
0.28
0.34
0.39
0.44
0.47
0.50
0.61
0.69
0.77
0.84
0.94
1.02
1.06
1.09
1.41
1.87
2.66
45%
SOLIDS
0.28
0.35
0.42
0.51
0.58
0.65
0.69
0.74
0.90
1.02
1.13
1.25
1.39
1.50
1.57
1.62
2.08
2.77
3.93
50%
SOLIDS
0.35
0.43
0.52
0.63
0.72
0.81
0.86
0.92
1.12
1.26
1.41
1.55
1.72
1.87
1.95
2.01
2.58
3.45
4.36
5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0
5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0
120
110
95
90
84
79
72
64
59
54
50
45
42
36
35
33
28
26
24
0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140
VOLUME
18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0
TRI-HELICAL CELL
5%
15%
25%
SOLIDS
SOLIDS
SOLIDS
0.64
0.95
1.40
0.73
1.08
1.60
0.94
1.39
2.05
1.03
1.52
2.25
1.14
1.69
2.50
1.18
1.75
2.58
1.32
1.95
2.88
1.50
2.22
3.28
1.61
2.39
3.53
1.76
2.60
3.85
1.91
2.83
4.18
2.14
3.17
4.68
2.19
3.25
4.80
2.64
3.91
5.78
2.80
4.09
5.98
2.81
4.16
6.15
3.22
4.77
7.05
3.81
5.63
8.33
4.09
6.05
8.95
35%
SOLIDS
2.07
2.37
3.03
3.33
3.70
3.81
4.26
4.85
5.22
5.70
6.18
6.92
7.10
8.55
8.74
9.10
10.43
12.32
13.24
45%
SOLIDS
3.07
3.51
4.49
4.93
5.48
5.64
6.30
7.18
7.73
8.44
9.15
10.25
10.52
12.66
13.10
13.48
15.45
18.25
19.62
50%
SOLIDS
3.80
4.35
5.57
6.11
6.79
6.99
7.81
8.89
9.57
10.46
11.34
12.70
13.04
15.68
16.23
16.70
19.15
22.61
24.31
QUADRANGULAR CELL
5%
15%
25%
SOLIDS SOLIDS SOLIDS
0.18
0.26
0.38
0.22
0.32
0.48
0.26
0.39
0.58
0.24
0.39
0.64
0.37
0.54
0.80
0.41
0.60
0.90
0.44
0.65
0.96
0.47
0.69
1.02
0.57
0.84
1.25
0.64
0.95
1.41
0.72
1.06
1.57
0.79
1.17
1.73
0.88
1.30
1.92
0.95
1.40
2.08
0.99
1.47
2.18
1.02
1.51
2.24
1.31
1.95
2.88
1.76
2.60
3.84
2.49
3.68
5.44
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170
CELL DEPTH
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170
50%
SOLIDS
1.21
1.50
1.80
2.20
2.50
2.81
3.00
3.20
3.90
4.41
4.90
5.41
6.01
6.50
6.81
7.01
9.01
12.02
15.18
45%
SOLIDS
0.77
0.96
1.16
1.42
1.61
1.80
1.94
2.06
2.52
2.83
3.16
3.48
3.87
4.19
4.39
4.51
5.80
7.74
10.96
50%
SOLIDS
0.96
1.20
1.44
1.76
2.00
2.24
2.40
2.56
3.12
3.53
3.92
4.33
4.81
5.20
5.45
5.61
7.21
9.61
12.14
45%
SOLIDS
0.32
0.40
0.48
0.59
0.66
0.74
0.80
0.85
1.04
1.17
1.30
1.44
1.60
1.73
1.81
1.86
2.39
3.19
4.52
50%
SOLIDS
0.40
0.49
0.60
0.73
0.83
0.93
0.99
1.06
1.29
1.45
1.62
1.79
1.98
2.15
2.25
2.31
2.97
3.97
5.01
VOLUME
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170
5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0
OFFSET GRAVURE
CHART #14
CELL DEPTH
VOLUME
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170
5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0
CELL DEPTH
CELL DEPTH
VOLUME
0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140
18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0
VOLUME
0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140
18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0
OFFSET GRAVURE
CHART #15
CELL DEPTH
VOLUME
0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140
18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0
TRI-HELICAL CELL
5%
15%
25%
SOLIDS SOLIDS SOLIDS
0.51
0.76
1.12
0.58
0.86
1.28
0.75
1.11
1.64
0.82
1.22
1.80
0.91
1.35
2.00
0.95
1.40
2.06
1.05
1.56
2.30
1.20
1.77
2.62
1.29
1.91
2.82
1.41
2.08
3.08
1.53
2.26
3.34
1.71
2.53
3.74
1.76
2.60
3.84
2.11
3.13
4.62
2.24
3.27
4.78
2.25
3.33
4.92
2.58
3.81
5.64
3.05
4.51
6.66
3.27
4.84
7.16
35%
SOLIDS
1.66
1.90
2.42
2.66
2.96
3.05
3.41
3.88
4.18
4.56
4.94
5.54
5.68
6.84
6.99
7.28
8.34
9.86
10.59
45%
SOLIDS
2.46
2.81
3.59
3.94
4.38
4.51
5.04
5.74
6.18
6.75
7.32
8.20
8.42
10.13
10.48
10.78
12.36
14.60
15.70
50%
SOLIDS
3.04
3.48
4.46
4.89
5.43
5.59
6.25
7.11
7.66
8.37
9.07
10.16
10.43
12.54
12.98
13.36
15.32
18.09
19.45
TRI-HELICAL CELL
5%
15%
25%
SOLIDS SOLIDS SOLIDS
0.41
0.61
0.90
0.47
0.69
1.02
0.60
0.89
1.31
0.66
0.97
1.44
0.73
1.08
1.60
0.76
1.12
1.65
0.84
1.25
1.84
0.96
1.42
2.10
1.03
1.53
2.26
1.12
1.66
2.46
1.22
1.81
2.68
1.37
2.03
3.00
1.40
2.08
3.07
1.69
2.50
3.70
1.79
2.62
3.83
1.80
2.66
3.94
2.06
3.05
4.51
2.44
3.60
5.33
2.62
3.87
5.73
35%
SOLIDS
1.32
1.52
1.94
2.13
2.37
2.44
2.73
3.10
3.34
3.65
3.96
4.43
4.54
5.47
5.59
5.82
6.68
7.88
8.47
45%
SOLIDS
1.96
2.25
2.87
3.16
3.51
3.61
4.03
4.60
4.95
5.40
5.86
6.56
6.73
8.10
8.38
8.63
9.89
11.68
12.56
50%
SOLIDS
2.43
2.78
3.56
3.91
4.35
4.47
5.00
5.69
6.12
6.69
7.26
8.13
8.35
10.04
10.39
10.69
12.26
14.47
15.56
TRI-HELICAL CELL
5%
15%
25%
SOLIDS SOLIDS SOLIDS
0.17
0.25
0.37
0.19
0.29
0.42
0.25
0.37
0.54
0.27
0.40
0.59
0.30
0.45
0.66
0.31
0.46
0.68
0.35
0.51
0.76
0.40
0.59
0.87
0.43
0.63
0.93
0.46
0.69
1.02
0.50
0.75
1.10
0.57
0.84
1.24
0.58
0.86
1.27
0.70
1.03
1.53
0.74
1.08
1.58
0.74
1.10
1.62
0.85
1.26
1.86
1.01
1.49
2.20
1.08
1.60
2.36
35%
SOLIDS
0.55
0.63
0.80
0.88
0.98
1.01
1.12
1.28
1.38
1.50
1.63
1.83
1.87
2.26
2.31
2.40
2.75
3.25
3.50
45%
SOLIDS
0.81
0.93
1.19
1.30
1.45
1.49
1.66
1.90
2.04
2.23
2.42
2.71
2.78
3.34
3.46
3.56
4.08
4.82
5.18
50%
SOLIDS
1.00
1.15
1.47
1.61
1.79
1.85
2.06
2.35
2.53
2.76
2.99
3.35
3.44
4.14
4.28
4.41
5.06
5.97
6.42
DIRECT GRAVURE
BACKING; LINESPEED
Undercut Required
BACKING/GRAVURE = 3/8 NIP
GRAVURE; 90% to 110% LINESPEED
REVERSE GRAVURE
BACKING; LINESPEED
Undercut required
BACKING/GRAVURE = 3/8 NIP
GRAVURE; 50% to 150% OF LINESPEED
OFFSET GRAVURE
BACKING; LINESPEED
BACKING/OFFSET =3/8 NIP
OFFSET; 95% to 105% OF LINESPEED
Undercut Required
OFFSET/GRAVURE = 3/8 NIP
GRAVURE; 10% to 25% OF LINESPEED
SMOOTH ROLL
BACKING; LINESPEED
NO Undercut Required
BACKING/PICKUP = VARY NIP
PICKUP;20% to 150% LINESPEED
COAT WEIGHT
NIP WIDTH & ROLL SPEED
Coat weight control is dependent upon the relationship of
linespeed vs. nip width and pickup roll speed
By increasing pickup roll speed the coat weight increases
By decreasing the pickup roll footprint the coat weight
increases
Other coat weight variables
coating solids
coating viscosity
Roll vs. Speed
3/8" nip
Coatweight
1/2" nip
3/4" nip
Roll spee d
CHECKING NIP
IMPRESSIONS
RUBBER
COVERED
ROLL
FOOTPRINT
LOAD
STEEL ROLL
Forward
Gravure
Offset
Gravure
Smooth
Transfer
100%
150%
GSM
50%
Gravure Speed
GSM
GSM
GSM
95%
100%
105%
10%
Gravure Speed
60%
10%
100%
Gravure Speed
100%
Pick-up Speed
Gravure
GSM
Smooth Roll
Line Speed
Coater
Selection
Direct
Gravure
Reverse
Gravure
Offset
Gravure
Smooth
Roll
No
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
No
Ability to Coat
Printed Film
Yes
No
Yes
Yes
Yes
No
Yes
Yes
Ability to Adjust
Coat Weight
Ability to Coat
Paper
Ability to Coat
Film
Requires Undercut
Rubber Roll
Thank You
PRESENTED BY
Lee A. Ostness
Product Manager Coating & Drying Systems
Black Clawson Converting Machinery
ostnessl@bc-egan.com