Presented by

Shrikant Athavale
On 12 th march 2010
Various kinds of coatings are being used.

• Adhesives
• Barrier coats
• Anti Fungus / Anti Curl coatings
• Sealable coatings
• Release Coatings
• Varnishes / Lacquers

These coatings are meant for Plastic films,

paper , Metal Foils etc.
 The surface preparation is a very important step while
coating on these substrates.

The backing / Carrier material is the most important

component of coated products .
The backing or carrier provided the necessary strength and
body to end product.
The backing has to be sufficiently strong . the backing needs to
have reasonably good tensile strength , elongation ,
conformability, moderate heat resistance , chemical resistance,
abrasion resistance etc.
The various backing materials that are common in use are
Plastic films
Paper
Metal Foils

The backing materials need a primer coat or chemical or

physical , surface preparation / treatment before adhesive
coating.
Plastics Films are widely used in Packaging applications such as
Self Adhesive Tapes, Laminates, Printing etc.

As we know all these films are chemically inert and have very low
surface energy. The below mentioned table gives an idea about
the surface tension of various polymers.

From the tables given below it is very clear that the polymer
surfaces need treatment to enhance the wet ability , printability ,
and adhesion properties. Or in other words the surface tension
has to match that of the coating materials.
Measuring Surface Energy
The object of surface treating is to improve the wettability of the
surface, thereby improving
the ability to bond to solvents, adhesives, coatings, and extrusion
coating. In order for a surface
to be properly wet by a liquid, the surface energy of the plastic
must be higher than the surface
tension of the liquid. Surface energy is measured in dynes per
centimeter. Ideally, the surface
energy of the plastic should be 7 to 10 dynes/cm higher than the
surface tension of the solvent
or liquid. For example, a printing ink having a surface tension of 30
dynes/cm would not
4
adequately wet or bond to a material having a surface energy less
than 37 to 40 dynes/cm (see
Figure 3).
Treated

untreated
One method for measuring surface energy known as the Wetting
Tension Test (ASTM D-2578) was established a number of years ago
(10).
Surface energy testing is frequently done on post-treatment surfaces
prior to follow-on converting processes.
With this test, a series of mixed liquids with gradually increasing
surface tensions are applied to a treated substrate surface until one is
found that just wets the surface.
The surface energy of the plastic is approximately equal to the
surface tension of that particular mixture. Test solutions are
available from various manufacturers of corona treating equipment.
Table below details the ratio of Formamide and Cellosolve™ for
various surface tensions.
Cellosolve™ is a registered trademark of Union Carbide for ethylene
glycol monoethylether.
The wetting tension test method is by far the most prevalent
measurement used to determine treatment level of post-treated
surfaces.
Dyne level
measuring procedures
Surface treatment techniques

The common methods of surface treatment for films are

• chemical etching
• flame treatment
• carona treatment
• plasma treatment

however chemical etching method is outdated.

Flame treatment
In this process propane or butane flame is used to treat the
polymer surface. Here the electron density is lower and
therefore the ionization rate .
The higher temp in the flame poses a problem for most
polymer surfaces.
Four variables control the optimum treatment conditions of a flame,
they are:
1. Air-to-Gas Ratio
2. BTU (kj) Output of the Burner
3. Distance of Surface from Flame Tips
4. Dwell Time of Surface in Oxidizing Zone
Carona treatment
Generally, plastics have chemically inert and nonporous
surfaces with low surface tensions causing them to be
non-receptive to bonding with printing inks. For
example,
polyethylene and polypropylene are known to have an
extremely low surface energy.
To activate substrates and make them receptive to ink
adhesion printers employ corona treaters. Corona
treaters increase the surface energy of substrates by
oxidizing the surface and creating positive and negative
sites on the surface by adding and deleting electrons.
What does corona do to the film
surface ?

• Forms low-molecular-weight (LMWOM) on film

surface

• Oxidizes film surface

• Forms positive and negative sites by adding

and
deleting electrons
A corona treating system is designed to increase the surface energy of
plastic films, foils
and paper in order to allow improved wettability and adhesion of inks,
coatings and adhesives.
As a result, the materials treated will demonstrate improved printing and
coating quality, and
stronger lamination strength.
The system consists of two major components:
1. the power supply, and
2. the treater station.
The power supply accepts standard 50/60 Hz utility electrical power and
converts it into
single phase, higher frequency (nominally 10 to 30 kHz) power that is
supplied to the treater
station.
The treater station applies this power to the surface of the material,
through an air gap, via a
pair of electrodes, one at high potential and the other, usually a roll
which supports the material,
at ground potential. Only the side of the material facing the high
potential electrode should
show an increase in surface tension
A corona treating system in its simplest form

Voltage is applied to the top plate which, in the case of a corona

treating system, would be the
electrode. The dielectric portion of the capacitor would be made
up of some type of roll
covering, air, and substrate in the corona treating system. The
final component, or bottom
plate, would take the form of an electrically grounded roll. In the
corona treating system, the
voltage buildup ionizes the air in the air gap, creating a corona
which will increase the surface
tension of the substrate passing over the electrically grounded
Plasma Treatment

What is Atmospheric Plasma?

• Like Corona, Plasma is the electrical ionization of a gas

• The Plasma (glow) discharge creates a smooth,
undifferentiated cloud of ionized gas with no visible
electrical filaments
• Unlike Corona, Plasma is created at much lower voltage
levels.
• In both cases, the power level may be identical
Effects of plasma on surfaces:

Electron bombardment crosslinking

Ion bombardment surface etching

Excitation of plasma gas chemical

surface reactions

UV radiation electron
bombardment
Atmospheric Plasma Benefits

• High Treatment Level

• Elimination of Backside Treatment

• Long-Lasting Surface Activation

• Elimination of Pin-Holing, Ozone

Surface Morphology Unaffected
Coating is a very Important process
involved in Manufacture of Coated
Products
Today we shall review some of these as listed below.
Gravure Coating
Comma Coating
Reverse Roll Coating
Hot Melt Coating
Metering Rod / Myer Bar Coating
Knife over roll coating
Slot Orifice coating
Immersion / Dip coating
Curtain Coating
 The Coating methods

Their Capabilities and Limitations

Max Coating Wt .
Coating Viscosity Speed gm per sq.
Method in CPS per Min 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
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
We will study
Comma coating
Reverse roller coating and
Metering Rod / Myer Bar Coating
Today
file:///D:/SHRIKANT/PSA%20BOOK/Coating%20Methods/Coating%20methods%20animation_files/revrol02.gif
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.
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, sometimes 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.
file:///D:/SHRIKANT/PSA%20BOOK/Coating%20Methods/Coating%20methods%20animation_files/meterod3.gif
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.
Figure 1 : 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 m2/l g/m2
1 0.15 3.8 263 3.8
3 0.3 7.6 131 7.6
4 0.4 10.2 98.4 10.2
5 0.5 12.7 78.7 12.7
6 0.6 15.2 65.6 15.2
8 0.8 20.3 49.2 20.3
10 1.0 25.4 39.4 25.4
12 1.2 30.5 32.8 30.5
15 1.5 38.1 26.3 38.1
18 1.8 45.7 21.9 45.7
22 2.2 55.9 17.9 55.9
24 2.4 60.3 16.1 60.3
30 3.0 76.2 13.1 76.2
42 4.2 107 9.2 107
19 5.0 127 7.9 127
80 8.0 200 4.9 203
100 10.0 254 3.9 254

1 in = 1,000 mils; 1 mm = 1,000 microns.

Thickness varies somewhat, notably for high viscosity liquids and small wire rods.
Barrier coatings

Normally paper is coated with some specialty coatings.

Why paper is coated ?

The four main reasons for coating paper are increased

• printability
• smoothness
• gloss
• brightness
Printability (the faithfulness of an image’s
reproduction) is clearly better when the ink does
not penetrate the paper’s fibers and spread out.
By printing on a coated sheet, the ink is applied to
the coating instead of the fibers; and the coating
has just enough porosity to improve drying speed,
but not enough to spread the ink. However, the
consistency of the ink holdout is dependent on the
method used in applying the coating.

Smoothness is achieved when the coating fills in

the valleys of the base sheet, and a smoother
surface is easier to print on. However, the degree
of smoothness is greatly determined by the
method used in applying the coating.
The microphotograph on the left reveals the rough surface of
an uncoated offset sheet. The photo on the right shows the
same type of sheet after coating and supercalendering.
A sheet’s smoothness determines its gloss. Coated papers’
three levels of gloss—matte, dull, and enamel—are usually the
result of the amount of polishing that the coating receives.
Matte coated papers are not polished; dull coated papers
receive moderate polishing; and enamel papers receive a high
degree of polishing. An exception to this rule will be explained
later.

Coated papers can achieve higher brightness levels than

uncoated sheets because the coating pigments can be bleached
more heavily than can cellulose fibers (excessive bleaching
weakens the fibers).
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.
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.
Anti fungus
is a highly versatile Isothiazolone based biocide and antimicrobial
used in all water containing formulations to prevent bacteria growth
and odours. The dose levels are extremely low for this highly effective
product.

Anti Curl

Sealable coatings – both Hot and cold

We have discussed this in detail

Release coating – Silicone , or non silicone

Release coating are based on Silicone Polymers
There is a wide choice now a days
They are available with
Water base , solvent base or solvent less technology.
The silicone polymer meant for release coating is mixed with a cross
linking catalyst , generally in the proportions of n10: 1 , diluted with ,
water or solvent , and the solution is coated , using Gravure Coating
technology , on Paper , Films , Metal Foil etc.
The coated web is passed through drying and curing Hot Air Tunnel.
Varnishes / Lacquers for overlay, scratch off , peeloff
Overprint varnishes are to enhance and protect the
printed substrate. They are applied with special coating
units that are predominantly coupled in-line to the
printing press; that is to say, after single or multicolor
prints, the varnish application takes place immediately.
.Various varnishes are used,depending on the requirements for the
coating, and thetransfer technology used.

Oil-based Varnishes
Oil-based varnishes can be compared to colorless offset
printing inks. The main components are resins, drying
oils, mineral oils, and drying agents. The oil-based
varnishes are transferred onto the paper with offset
inking units. They dry on the paper by absorption and
oxidation. Oil-based varnishes are used to:
• increase printing ink brilliance (glossy varnishes),
• achieve specific matte effects (matte varnishes and
satin finish varnishes),
• improve abrasion resistance (protective varnishes).
Oilprint varnishes tend to turn yellow. For web offset
printing, special heat-set varnishes are used.
Water-based/Dispersion Varnishes
Today, dispersion varnishes are widely used and offer
diverse technical possibilities in offset printing. The
principal components of dispersion varnishes are:
• polymer dispersions,
• hydrosols (resins dissolved in water),
• wax dispersions for grinding and abrasion resistance,
• film-forming aids,
• cross-linking agents and antifoaming agents.

Dispersion varnishes dry extremely quickly. They are

therefore not used in standard offset inking units but
in special coating units that only have few rollers or
work with a chambered doctor blade system.
The drying takes place purely physically by evaporation
of the water, often supported by hot air application.
As soon as a part of the water contained in the varnish
is removed, the surface becomes non-tacky.
The most significant advantages of these modern varnishes are:
• odor free,
• rapid film formation (drying),
• no yellowing,
• zero, or only slight, powder spraying in the delivery
on sheet-fed printing presses necessary,
• high processing speed,
• smooth surface,
• dilutable and washable with water.

The following qualities of the printed product are

achieved by coating with a dispersion varnish:
• abrasion protection, scuff resistance in a wet condition
(labels),
• high gloss, silk finish, or matte effects,
• hot-seal resistance,
• gliding quality,
• deep freeze resistance,
• fixing of metallic inks.
Other special functional varnishes that fulfill an additional
task alongside surface finishing are:

• blister varnishes to enable adhesion for blister

packaging
• primer (bonding agent), for instance, for further
UV varnish finishing,
• varnishes that can be ultrasonically welded for special finishing
methods,
• scented varnishes (varnishes with micro-encapsulated aromatics),
• label varnishes,
• two-component varnishes (varnish and hardener).

Dispersion varnishes are also used for surface finishing

in gravure printing. They are essentially identical to the
dispersion varnishes used for offset printing.The principal
difference lies in the typically much lower viscosity
of those varnishes used in gravure printing.The following
categories of aqueous dispersion varnishes are
offered for gravure printing:
• preprint and intermediate print varnishes,
• high gloss and matte finishing varnishes,
• special varnishes, for instance, calendar varnishes
Solvent-based Varnishes
Varnishes containing solvents are varnishes in which
resin components are dissolved in organic solvents.
The hardening takes place through evaporation of the
solvent. The varnishes are called nitro varnishes, or nitro
combination-varnishes, and are applied in a separate
process with coating machines.
Solvent-containing gravure printing varnishes are of
similar composition to solvent-containing gravure
printing inks. The drying of these one-component varnishes
takes place purely physically.
Two-component
varnishes for gravure printing consist of the actual varnish
and a hardening component.The cross-linking reaction
begins the moment the hardening agent is added
to the varnish.When running through the hot air dryer
of the press, the two-component varnish receives an
energy feed,which induces the further cross-linking reaction
in the film. In the course of five to seven days the
varnish layer hardens fully. It is then heat-resistant and
resistant to many chemicals.
UV Varnishes
UV varnishes are varnishes cured under UV radiation.
They have a similar composition to UV inks – and are
therefore completely different to oil-based and dispersion
varnishes – and thus contain no volatile substances.