Coating Technology for Flexible Packaging Lee A. Ostness

Product Manager - Coating & Drying Systems Flexible Packaging is widely used in today’s world. It is used to package a multitude of products such as: processed meat, processed cheese, fresh red meat, bulk liquids, cereals, cake mix, coffee, medical device films, snacks and many others. There are many different substrates and coatings used to create these packages to produce the various levels of barrier protection. see chart

SUBSTRATES COATINGS PET 1 – 10 mil Primers 0.04 – 0.4 gsm PE 1 – 8 mil Adhesives 3.25 – 6.5 gsm Al Foil 20 – 60 µ PVDC 1.6 – 6.5 gsm BOPP/OPP 0.4 – 2 mil Wash-coats 0.8 – 1.5 gsm CPP 1 – 4 mil PVOH 0.5 gsm Nylon 0.4 – 2 mil Lacquers 5.0 gsm MetPET 1 – 10 mil Varnishes 0.02 – 0.04 gsm Cellophane 0.8 – 1 mil Acrylic Polyurethanes 0.3 gsm

A typical package may be constructed of several layers of substrates and coatings. Two typical constructions are illustrated below. The beverage package is constructed with PET/Printed/Primer coating/LDPE/Foil/LDPE(heatseal). The Retort Package is a different construction requiring two coatings, PET/Printed/Adhesive coating/Foil/Primer coating/LDPE. The foil is a barrier layer and may be substituted with Metalized PET, Nylon, or EVOH depending on the amount or type of barrier required. see illustration

PET 12.6µ(PRINT)

FOIL 6.3µLDPE 12.6µ

LDPE (Heat Seal) 25µ

PRIMER 0.04µ

Beverage Package

PET 12.6µ(PRINT)

FOIL 6.3µADHESIVE 3.25 – 6.5µ

LDPE 25 µPRIMER 0.04µ

Retort Package

PET 12.6µ(PRINT)

FOIL 6.3µLDPE 12.6µ

LDPE (Heat Seal) 25µ

PRIMER 0.04µ

PET 12.6µ(PRINT)

FOIL 6.3µLDPE 12.6µ

LDPE (Heat Seal) 25µ

PRIMER 0.04µ

Beverage Package

PET 12.6µ(PRINT)

FOIL 6.3µADHESIVE 3.25 – 6.5µ

LDPE 25 µPRIMER 0.04µ

Retort Package

PET 12.6µ(PRINT)

FOIL 6.3µADHESIVE 3.25 – 6.5µ

LDPE 25 µPRIMER 0.04µ

PET 12.6µ(PRINT)

FOIL 6.3µADHESIVE 3.25 – 6.5µ

LDPE 25 µPRIMER 0.04µ

Retort Package

The constructions incorporate the use of solution coating(s) to enhance either the barrier and/or the adhesion properties. The focus of this paper is to discuss how these coatings are applied. A solution coating is a liquid with solids dispersed in the liquid to assist the wetting of the substrate it is applied to. The liquid can be a combination of solvents or water determined by its ability to maintain the dispersion of the solids. The solution coating is applied to a continuous web with a Coater and then passed through a Dryer to remove the liquid leaving a thin layer of solids on the substrate. The coater will be either a gravure type or a smooth roll type. The dryers are normally a roll support design or a floatation design. The roll support dryer consist of rolls supporting the web with opposing impingement nozzles drying the web. The floatation dryer consist of nozzles on both sides of the web creating a sign wave affect to float the web. Coating heads have a variety of applications, strengths and weaknesses. How do you objectively select the right coating head? There are 50 plus coater configurations available to apply an infinite number of coating solutions. To select the coater for your needs you first need to know your coating and substrate’s properties, then match these properties with the coater’s abilities/limitations.

Coating Substrate Coater % Solids Absorbency Speed Range Viscosity Surface Tension Coat Weight Range 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 gravure coaters utilize steel rolls with patterns engraved into the face of the roll. This pattern determines how much coating is carried to the web. The coating is applied to the gravure, metered off the surface, leaving coating only in the engraved pattern, then transferred to the web that is supported by the rubber covered back-up roll. The smooth roll coater applies the 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 vendor’s patterns

and the names associated with them. The patterns are called from left to

right; Tri-Helical, Pyramid, Quadrangular, and Hexagonal. The amount of coating in each cell (pattern) is measured and referred to as Billion Cubic Microns (BCM). To select the correct gravure pattern for your application, you need to reference a coat weight chart provided by most gravure vendors. On this chart locate your coat weight under the percent 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.

DirectGravure

ReverseGravure

OffsetGravure

SmoothRoll

DirectGravure

ReverseGravure

OffsetGravure

SmoothRoll

DirectGravure

ReverseGravure

OffsetGravure

SmoothRoll

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 explained as we discuss each type of coater and their operating parameters.

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 compound and is used to transport the web through the coating process. The back-up roll is pressed 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

GS

M

150%50% 100%Gravure Speed

GSM

95% 100% 105%

Gravure Speed

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. In the Direct Gravure mode the gravure roll and the web are moving in the same direction at the point of contact. The speed of the gravure roll is usually the same as the web but it may be adjusted to ∓10% of the web speed. The coat weight is determined by the gravure volume and the coating solids.

Reverse Gravure Coater: The Reverse Gravure Coater consists of the same equipment as the Direct Gravure coater. In this method the gravure roll runs in the opposite direction to the web and varies in speed from 50% to 150% of web speed. The most common operating speed is 110% to 120%. The coat weight in this mode when plotted will create a bell shaped curved by running the gravure roll from 50 to 150% of web speed measuring the coat weight every 10%. If the same gravure pattern from the Direct gravure is used

the highest coat weight will only be about 80% of the direct gravure methods. The coat weight is determined by the gravure pattern, the coating solids, and by the speed of the gravure roll. This method will lay the coating down with a smoother appearance because of the shearing action created at the nip. The appearance created by the direct

gravure method is a rougher texture because at matched speeds and in the same direction you are virtually printing the pattern onto the web.

10% 60% 100%Gravure Speed

GS

M

Offset Gravure Coater: The Offset Gravure Coater consist of a steel back-up roll, a rubber covered applicator roll, a gravure roll, and a coating applicator. The back-up roll is chrome plated steel roll used to transport the web through the coating process and create the nip between the web and the applicator roll. The Applicator roll is a rubber covered roll used to transfer the coating from the gravure roll to applicator roll, to the web. The gravure roll is a steel roll with a pattern engraved into its surface. The coating applicator is either an enclosed chamber with two doctor blades to an open pan with a doctor blade assembly to remove the excess coating. In this method all the rolls are turning in the same direction at the point of contact at each nip. The back-up roll is operating at line speed, the applicator roll most usually is operating at 98% of line speed (∓5%), and the gravure roll

operates at 25 to 35% of line speed. With this method the coat weight curve when plotted would be a steady incline then level off to a fairly straight plain. The curve would be generated by varying the speed of the gravure roll from 5% to 100 % in increments of 5%. The coat weight usually levels off when the gravure roll reaches

about the 60% of line speed. The shearing action created by the differential speeds and the two nip points generally apply a smooth coating. Smooth Roll Coater: The Smooth Roll Coater consist of a rubber covered back-up roll, a steel chrome plated pick-up roll, sling guards and a coating pan. The back-up roll is covered with a rubber compound and is used to transport the web through the coating process. The back-up roll is pressed against the pick-up roll creating a slight nip. The pick-up roll is 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

10% 100%

Pick-up Speed

GSM

¼”¼”

½”½”

¾”¾”

at this nip point. The amount of coating applied is dependent on the hydraulic forces at the coater nip created by the speed of the pick-up roll 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. The rubber compound selected has to consider several operational conditions. The parameters consist of the durometer, surface tension, resilience, tear resistance. The durometer needs to be based on the speed of the machine line and the viscosity of the coating. 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 with a slow incline and then when the hydraulic forces overcome the nip the line transitions into a steep incline. The wider the nip the lower on the graph the curve is generated.

The gravure coater requires the rubber rolls to be undercut slightly narrower than the web width whereas in the smooth roll method the rubber rolls are full width. When the coating is transferred to the web or applicator roll from the gravure cells it only needs to be 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? There are several methods available using carbon nip paper, aluminum foil, liquid coating and piece of paper, a computerized nip blanket. What all these methods have in common is you must place something between the two rolls before you close them together.

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).

GS

M

150%50% 100%Gravure Speed

ReverseGravure

GSM

95% 100% 105%

Gravure Speed

ForwardGravure

10% 60% 100%Gravure Speed

GSM

OffsetGravure

10% 100%

Pick-up Speed

GSM

SmoothTransfer

¼”

½”

¾”

GS

M

150%50% 100%Gravure Speed

ReverseGravure

GS

M

150%50% 100%Gravure Speed

ReverseGravure

150%50% 100%Gravure Speed

ReverseGravure

GSM

95% 100% 105%

Gravure Speed

ForwardGravure

10% 60% 100%Gravure Speed

GSM

OffsetGravure

10% 100%

Pick-up Speed

GSM

SmoothTransfer

¼”

½”

¾”

GSM

95% 100% 105%

Gravure Speed

ForwardGravure

10% 60% 100%Gravure Speed

GSM

OffsetGravure

10% 60% 100%Gravure Speed

GSM

OffsetGravure

10% 100%

Pick-up Speed

GSM

SmoothTransfer

10% 100%

Pick-up Speed

GSM

SmoothTransfer

¼”¼”

½”½”

¾”¾”

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 sleeve system allows the rubber undercut sleeve to be changed in less than 15 minutes. This system still requires a sleeve for each web width. The smooth roll coater offers coat weight control but needs adjustment going from low to high line speeds. This is referred to as unstable, as

IMPRESSIONPAPER

TORQUE SHAFTSHOULD BELEVELED

RUBBERCOVEREDROLL

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.

GS

M

Line Speed

GravureSmooth Roll

GS

M

Line Speed

GravureSmooth Roll

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.

Coater Selection

Direct Gravure

Reverse Gravure

Offset Gravure

Smooth Roll

Ability to Adjust Coat Weight No Yes Yes Yes Ability to Coat Paper Yes Yes Yes No Ability to Coat Film Yes Yes Yes Yes

Stable at all Line Speeds Yes Yes Yes No Requires Under Cut Rubber Roll Yes Yes Yes No

Ability to Coat Printed Film Yes No Yes Yes Ability to Coat Foil Yes No Yes Yes

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2006 PLACE Conference

September 17-21 Cincinnati, Ohio

Coating Technologyfor Flexible Packaging

Presented by:Lee A. OstnessProduct Manager Coating & Drying SystemsBlack Clawson Converting Machinery

Typical ProductsProduct•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 ComponentsSubstrates•PET 1-10 mil•PE 1-8 mil•Al foil 20-60 µ•BOPP/OPP 0.4-2 mil•CPP 1-4 mil •Nylon 0.4-2 mil•METPET 1-10 mil•Cellophane 0.8-1 mil

Coatings•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

2

Typical Product Structures

PET 12.6µ(PRINT)

FOIL 6.3µLDPE 12.6µ

LDPE (Heat Seal) 25µ

PRIMER 0.04µ

Beverage Package

PET 12.6µ(PRINT)

FOIL 6.3µADHESIVE 3.25 – 6.5µ

LDPE 25 µPRIMER 0.04µ

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/DRYERCoater

Smooth roll Backing Roll not UndercutPan Fed

Direct GravureBacking Roll Undercut

SleevePan FedEnclosed Applicator

DryerAir Floatation NozzlesRoll Support

3

FLEX-PACK COATERS

DirectGravure

ReverseGravure

OffsetGravure

SmoothRoll

Methodology of Application

Gravure Coater Smooth Roll Coater

Gravure Engraved Patterns

4

Volume “BCM”

Billion Cubic Microns

The formula is based on ink technology. Many oftoday's coatings are ofan unique composition.Use this formula for abetter understanding ofhow the cell volumes areachieved. Coat weights may vary when different coatings are applied with the same cell volume.

formula from Consolidated Engravers

DIRECT GRAVURE: is 80 % of what the chart displays REVERSE GRAVURE: is generally 80% of Direct GravureDIFFERENTIAL OFFSET GRAVURE: is generally 25% of Direct Gravure

CHARTS REFERENCED FROM:PAMARCO, INC.

200 0.0008 2.6 0.21 0.26 0.32 0.47 0.70 200 0.0012 5.7 0.22 0.32 0.48 0.71 1.05 1.31 120 0.0022 18.0 0.64 0.95 1.40 2.07 3.07 3.80 ARC INDUSTRIES, INC.180 0.0009 3.2 0.23 0.29 0.36 0.53 0.79 190 0.0015 7.5 0.27 0.40 0.60 0.89 1.31 1.63 110 0.0025 20.3 0.73 1.08 1.60 2.37 3.51 4.35 AMERICAN ENGRAVING AND MACHINE CO.165 0.0010 3.4 0.26 0.32 0.40 0.59 0.88 180 0.0018 9.4 0.33 0.48 0.72 1.07 1.58 1.96 95 0.0032 26.2 0.94 1.39 2.05 3.03 4.49 5.57 MODERN ENGRAVING AND MACHINE CO.150 0.0020 7.5 0.51 0.64 0.80 1.18 1.75 165 0.0022 10.9 0.30 0.49 0.80 1.30 1.93 2.39 90 0.0035 28.8 1.03 1.52 2.25 3.33 4.93 6.11142 0.0022 8.2 0.56 0.70 0.88 1.30 1.92 150 0.0025 13.3 0.46 0.68 1.00 1.48 2.19 2.72 84 0.0039 32.3 1.14 1.69 2.50 3.70 5.48 6.79132 0.0025 9.7 0.64 0.80 1.00 1.48 2.19 140 0.0028 15.0 0.51 0.76 1.12 1.66 2.45 3.05 79 0.0040 32.7 1.18 1.75 2.58 3.81 5.64 6.99120 0.0030 11.0 0.77 0.96 1.20 1.78 2.63 130 0.0030 16.0 0.55 0.81 1.20 1.78 2.63 3.26 72 0.0045 36.8 1.32 1.95 2.88 4.26 6.30 7.81116 0.0032 11.9 0.81 1.02 1.28 1.89 2.80 120 0.0032 17.2 0.59 0.87 1.28 1.89 2.80 3.48 64 0.0051 41.8 1.50 2.22 3.28 4.85 7.18 8.89108 0.0033 12.2 0.85 1.06 1.32 1.95 2.89 110 0.0039 21.4 0.71 1.05 1.56 2.31 3.42 4.24 59 0.0055 45.0 1.61 2.39 3.53 5.22 7.73 9.57100 0.0035 13.9 1.03 1.20 1.40 2.07 3.07 96 0.0044 26.3 0.80 1.19 1.76 2.61 3.85 4.79 54 0.0060 49.0 1.76 2.60 3.85 5.70 8.44 10.4690 0.0038 16.0 0.98 1.22 1.52 2.25 3.33 85 0.0049 30.0 0.90 1.32 1.96 2.90 4.29 5.33 50 0.0065 53.3 1.91 2.83 4.18 6.18 9.15 11.3480 0.0040 17.3 1.02 1.28 1.60 2.37 3.50 75 0.0054 32.0 0.98 1.46 2.16 3.20 4.73 5.88 45 0.0073 59.6 2.14 3.17 4.68 6.92 10.25 12.7070 0.0045 18.0 1.15 1.44 1.80 2.66 3.94 65 0.0060 35.4 1.10 1.62 2.40 3.55 5.26 6.53 42 0.0075 61.5 2.19 3.25 4.80 7.10 10.52 13.0465 0.0050 20.4 1.28 1.60 2.00 2.96 4.38 55 0.0065 40.4 1.19 1.76 2.60 3.85 5.69 7.07 36 0.0090 73.3 2.64 3.91 5.78 8.55 12.66 15.6860 0.0058 24.4 1.49 1.86 2.32 3.43 5.08 45 0.0068 44.5 1.24 1.84 2.72 4.03 5.96 7.40 35 0.0093 76.0 2.80 4.09 5.98 8.74 13.10 16.2355 0.0062 26.6 1.58 1.98 2.48 3.67 5.43 35 0.0070 46.6 1.28 1.89 2.80 4.14 6.13 7.62 33 0.0096 78.2 2.81 4.16 6.15 9.10 13.48 16.7050 0.0076 33.7 1.94 2.42 3.02 4.47 6.61 30 0.0090 58.7 1.64 2.43 3.60 5.33 7.88 9.79 28 0.0110 90.0 3.22 4.77 7.05 10.43 15.45 19.1545 0.0090 41.0 2.30 2.88 3.60 5.33 7.88 25 0.0120 81.0 2.19 3.25 4.80 7.10 10.51 13.06 26 0.0130 106.5 3.81 5.63 8.33 12.32 18.25 22.6140 0.0104 48.0 2.67 3.33 4.16 6.15 9.11 16 0.0170 117.0 3.11 4.60 6.80 10.06 14.89 16.50 24 0.0140 115.0 4.09 6.05 8.95 13.24 19.62 24.31

DIRECT FORWARD GRAVURE

0.0008 2.6 0.17 0.21 0.26 0.38 0.56 0.0012 5.7 0.18 0.26 0.38 0.57 0.84 1.05 0.0012 5.7 0.20 0.30 0.44 0.65 0.97 1.21 0.0022 18.0 0.51 0.76 1.12 1.66 2.46 3.040.0009 3.2 0.19 0.23 0.29 0.42 0.63 0.0015 7.5 0.22 0.32 0.48 0.71 1.05 1.30 0.0015 7.5 0.25 0.37 0.55 0.82 1.21 1.50 0.0025 20.3 0.58 0.86 1.28 1.90 2.81 3.480.0010 3.4 0.20 0.26 0.32 0.47 0.70 0.0018 9.4 0.26 0.39 0.58 0.86 1.26 1.57 0.0018 9.4 0.30 0.45 0.66 0.98 1.45 1.80 0.0032 26.2 0.75 1.11 1.64 2.42 3.59 4.460.0020 7.5 0.41 0.51 0.64 0.94 1.40 0.0022 10.9 0.24 0.39 0.64 1.04 1.54 1.91 0.0022 10.9 0.28 0.45 0.74 1.20 1.78 2.20 0.0035 28.8 0.82 1.22 1.80 2.66 3.94 4.890.0022 8.2 0.45 0.56 0.70 1.04 1.54 0.0025 13.3 0.37 0.54 0.80 1.18 1.75 2.18 0.0025 13.3 0.42 0.62 0.92 1.36 2.01 2.50 0.0039 32.3 0.91 1.35 2.00 2.96 4.38 5.430.0025 9.7 0.51 0.64 0.80 1.18 1.75 0.0028 15.0 0.41 0.60 0.90 1.33 1.96 2.44 0.0028 15.0 0.47 0.70 1.03 1.53 2.25 2.81 0.0040 32.7 0.95 1.40 2.06 3.05 4.51 5.590.0030 11.0 0.61 0.77 0.96 1.42 2.10 0.0030 16.0 0.44 0.65 0.96 1.42 2.10 2.61 0.0030 16.0 0.50 0.74 1.10 1.64 2.42 3.00 0.0045 36.8 1.05 1.56 2.30 3.41 5.04 6.250.0032 11.9 0.65 0.82 1.02 1.51 2.24 0.0032 17.2 0.47 0.69 1.02 1.51 2.24 2.78 0.0032 17.2 0.54 0.80 1.18 1.74 2.58 3.20 0.0051 41.8 1.20 1.77 2.62 3.88 5.74 7.110.0033 12.2 0.68 0.85 1.06 1.56 2.31 0.0039 21.4 0.57 0.84 1.25 1.85 2.74 3.39 0.0039 21.4 0.65 0.97 1.44 2.13 3.15 3.90 0.0055 45.0 1.29 1.91 2.82 4.18 6.18 7.660.0035 13.9 0.82 0.96 1.12 1.66 2.46 0.0044 26.3 0.64 0.95 1.41 2.09 3.08 3.83 0.0044 26.3 0.74 1.09 1.62 2.40 3.54 4.41 0.0060 49.0 1.41 2.08 3.08 4.56 6.75 8.370.0038 16.0 0.78 0.98 1.22 1.80 2.66 0.0049 30.0 0.72 1.06 1.57 2.32 3.43 4.26 0.0049 30.0 0.82 1.22 1.80 2.67 3.95 4.90 0.0065 53.3 1.53 2.26 3.34 4.94 7.32 9.070.0040 17.3 0.82 1.02 1.28 1.90 2.80 0.0054 32.0 0.79 1.17 1.73 2.56 3.78 4.70 0.0054 32.0 0.91 1.34 1.99 2.94 4.35 5.41 0.0073 59.6 1.71 2.53 3.74 5.54 8.20 10.160.0045 18.0 0.92 1.15 1.44 2.13 3.15 0.0060 35.4 0.88 1.30 1.92 2.84 4.21 5.22 0.0060 35.4 1.01 1.49 2.21 3.27 4.84 6.01 0.0075 61.5 1.76 2.60 3.84 5.68 8.42 10.430.0050 20.4 1.02 1.28 1.60 2.37 3.50 0.0065 40.4 0.95 1.40 2.08 3.08 4.55 5.66 0.0065 40.4 1.09 1.62 2.39 3.54 5.23 6.50 0.0090 73.3 2.11 3.13 4.62 6.84 10.13 12.540.0058 24.4 1.19 1.49 1.86 2.74 4.06 0.0068 44.5 0.99 1.47 2.18 3.22 4.77 5.92 0.0068 44.5 1.14 1.69 2.50 3.71 5.48 6.81 0.0093 76.0 2.24 3.27 4.78 6.99 10.48 12.980.0062 26.6 1.26 1.58 1.98 2.94 4.34 0.0070 46.6 1.02 1.51 2.24 3.31 4.90 6.10 0.0070 46.6 1.18 1.74 2.58 3.81 5.64 7.01 0.0096 78.2 2.25 3.33 4.92 7.28 10.78 13.360.0076 33.7 1.55 1.94 2.42 3.58 5.29 0.0090 58.7 1.31 1.95 2.88 4.26 6.30 7.83 0.0090 58.7 1.51 2.24 3.31 4.90 7.25 9.01 0.0110 90.0 2.58 3.81 5.64 8.34 12.36 15.320.0090 41.0 1.84 2.30 2.88 4.26 6.30 0.0120 81.0 1.76 2.60 3.84 5.68 8.41 10.45 0.0120 81.0 2.02 2.99 4.42 6.53 9.67 12.02 0.0130 106.5 3.05 4.51 6.66 9.86 14.60 18.090.0104 48.0 2.13 2.66 3.33 4.92 7.29 0.0170 117.0 2.49 3.68 5.44 8.05 11.91 13.20 0.0170 117.0 2.86 4.23 6.26 9.26 13.70 15.18 0.0140 115.0 3.27 4.84 7.16 10.59 15.70 19.45

DIRECT REVERSE GRAVURE

0.0008 2.6 0.14 0.17 0.20 0.30 0.45 0.0012 5.7 0.14 0.21 0.31 0.45 0.67 0.84 0.0012 5.7 0.16 0.24 0.35 0.52 0.77 0.96 0.0022 18.0 0.41 0.61 0.90 1.32 1.96 2.430.0009 3.2 0.15 0.19 0.23 0.34 0.51 0.0015 7.5 0.17 0.26 0.38 0.57 0.84 1.04 0.0015 7.5 0.20 0.30 0.44 0.66 0.96 1.20 0.0025 20.3 0.47 0.69 1.02 1.52 2.25 2.780.0010 3.4 0.16 0.20 0.26 0.38 0.56 0.0018 9.4 0.21 0.31 0.46 0.68 1.01 1.25 0.0018 9.4 0.24 0.36 0.53 0.79 1.16 1.44 0.0032 26.2 0.60 0.89 1.31 1.94 2.87 3.560.0020 7.5 0.33 0.41 0.51 0.76 1.12 0.0022 10.9 0.19 0.32 0.51 0.83 1.24 1.53 0.0022 10.9 0.22 0.36 0.59 0.96 1.42 1.76 0.0035 28.8 0.66 0.97 1.44 2.13 3.16 3.910.0022 8.2 0.36 0.45 0.56 0.83 1.23 0.0025 13.3 0.29 0.43 0.64 0.95 1.40 1.74 0.0025 13.3 0.34 0.50 0.74 1.09 1.61 2.00 0.0039 32.3 0.73 1.08 1.60 2.37 3.51 4.350.0025 9.7 0.41 0.51 0.64 0.95 1.40 0.0028 15.0 0.33 0.48 0.72 1.06 1.57 1.95 0.0028 15.0 0.38 0.56 0.82 1.22 1.80 2.24 0.0040 32.7 0.76 1.12 1.65 2.44 3.61 4.470.0030 11.0 0.49 0.61 0.77 1.14 1.68 0.0030 16.0 0.35 0.52 0.77 1.14 1.68 2.09 0.0030 16.0 0.40 0.60 0.88 1.31 1.94 2.40 0.0045 36.8 0.84 1.25 1.84 2.73 4.03 5.000.0032 11.9 0.52 0.65 0.82 1.21 1.79 0.0032 17.2 0.38 0.55 0.82 1.21 1.79 2.23 0.0032 17.2 0.43 0.64 0.94 1.39 2.06 2.56 0.0051 41.8 0.96 1.42 2.10 3.10 4.60 5.690.0033 12.2 0.54 0.68 0.84 1.25 1.85 0.0039 21.4 0.46 0.67 1.00 1.48 2.19 2.71 0.0039 21.4 0.52 0.78 1.15 1.70 2.52 3.12 0.0055 45.0 1.03 1.53 2.26 3.34 4.95 6.120.0035 13.9 0.66 0.77 0.90 1.32 1.96 0.0044 26.3 0.51 0.76 1.13 1.67 2.46 3.07 0.0044 26.3 0.59 0.87 1.30 1.92 2.83 3.53 0.0060 49.0 1.12 1.66 2.46 3.65 5.40 6.690.0038 16.0 0.63 0.78 0.97 1.44 2.13 0.0049 30.0 0.57 0.85 1.25 1.86 2.75 3.41 0.0049 30.0 0.66 0.97 1.44 2.13 3.16 3.92 0.0065 53.3 1.22 1.81 2.68 3.96 5.86 7.260.0040 17.3 0.66 0.82 1.02 1.52 2.24 0.0054 32.0 0.63 0.93 1.38 2.05 3.03 3.76 0.0054 32.0 0.72 1.07 1.59 2.36 3.48 4.33 0.0073 59.6 1.37 2.03 3.00 4.43 6.56 8.130.0045 18.0 0.74 0.92 1.15 1.70 2.52 0.0060 35.4 0.70 1.04 1.54 2.27 3.37 4.18 0.0060 35.4 0.81 1.19 1.77 2.61 3.87 4.81 0.0075 61.5 1.40 2.08 3.07 4.54 6.73 8.350.0050 20.4 0.82 1.02 1.28 1.89 2.80 0.0065 40.4 0.76 1.12 1.66 2.46 3.64 4.52 0.0065 40.4 0.87 1.29 1.91 2.83 4.19 5.20 0.0090 73.3 1.69 2.50 3.70 5.47 8.10 10.040.0058 24.4 0.95 1.19 1.48 2.20 3.25 0.0068 44.5 0.79 1.17 1.74 2.58 3.81 4.74 0.0068 44.5 0.91 1.35 2.00 2.97 4.39 5.45 0.0093 76.0 1.79 2.62 3.83 5.59 8.38 10.390.0062 26.6 1.01 1.27 1.59 2.35 3.48 0.0070 46.6 0.82 1.21 1.79 2.65 3.92 4.88 0.0070 46.6 0.94 1.39 2.06 3.05 4.51 5.61 0.0096 78.2 1.80 2.66 3.94 5.82 8.63 10.690.0076 33.7 1.24 1.55 1.93 2.86 4.23 0.0090 58.7 1.05 1.56 2.30 3.41 5.04 6.27 0.0090 58.7 1.21 1.79 2.65 3.92 5.80 7.21 0.0110 90.0 2.06 3.05 4.51 6.68 9.89 12.260.0090 41.0 1.47 1.84 2.30 3.41 5.04 0.0120 81.0 1.40 2.08 3.07 4.54 6.73 8.36 0.0120 81.0 1.61 2.39 3.53 5.23 7.74 9.61 0.0130 106.5 2.44 3.60 5.33 7.88 11.68 14.470.0104 48.0 1.71 2.13 2.66 3.94 5.83 0.0170 117.0 1.99 2.94 4.35 6.44 9.53 10.56 0.0170 117.0 2.29 3.38 5.00 7.40 10.96 12.14 0.0140 115.0 2.62 3.87 5.73 8.47 12.56 15.56

0.0008 2.6 0.06 0.07 0.08 0.12 0.18 0.0012 5.7 0.06 0.09 0.13 0.19 0.28 0.35 0.0012 5.7 0.07 0.10 0.15 0.22 0.32 0.40 0.0022 18.0 0.17 0.25 0.37 0.55 0.81 1.000.0009 3.2 0.06 0.08 0.10 0.14 0.21 0.0015 7.5 0.07 0.11 0.16 0.23 0.35 0.43 0.0015 7.5 0.08 0.12 0.18 0.27 0.40 0.49 0.0025 20.3 0.19 0.29 0.42 0.63 0.93 1.150.0010 3.4 0.07 0.08 0.11 0.16 0.23 0.0018 9.4 0.09 0.13 0.19 0.28 0.42 0.52 0.0018 9.4 0.10 0.15 0.22 0.32 0.48 0.60 0.0032 26.2 0.25 0.37 0.54 0.80 1.19 1.470.0020 7.5 0.14 0.17 0.21 0.31 0.46 0.0022 10.9 0.08 0.13 0.21 0.34 0.51 0.63 0.0022 10.9 0.09 0.15 0.24 0.39 0.59 0.73 0.0035 28.8 0.27 0.40 0.59 0.88 1.30 1.610.0022 8.2 0.15 0.18 0.23 0.34 0.51 0.0025 13.3 0.12 0.18 0.26 0.39 0.58 0.72 0.0025 13.3 0.14 0.21 0.30 0.45 0.66 0.83 0.0039 32.3 0.30 0.45 0.66 0.98 1.45 1.790.0025 9.7 0.17 0.21 0.26 0.39 0.58 0.0028 15.0 0.13 0.20 0.30 0.44 0.65 0.81 0.0028 15.0 0.15 0.23 0.34 0.50 0.74 0.93 0.0040 32.7 0.31 0.46 0.68 1.01 1.49 1.850.0030 11.0 0.20 0.25 0.32 0.47 0.69 0.0030 16.0 0.14 0.21 0.32 0.47 0.69 0.86 0.0030 16.0 0.17 0.25 0.36 0.54 0.80 0.99 0.0045 36.8 0.35 0.51 0.76 1.12 1.66 2.060.0032 11.9 0.21 0.27 0.34 0.50 0.74 0.0032 17.2 0.15 0.23 0.34 0.50 0.74 0.92 0.0032 17.2 0.18 0.26 0.39 0.57 0.85 1.06 0.0051 41.8 0.40 0.59 0.87 1.28 1.90 2.350.0033 12.2 0.22 0.28 0.35 0.51 0.76 0.0039 21.4 0.19 0.28 0.41 0.61 0.90 1.12 0.0039 21.4 0.22 0.32 0.47 0.70 1.04 1.29 0.0055 45.0 0.43 0.63 0.93 1.38 2.04 2.530.0035 13.9 0.27 0.32 0.37 0.55 0.81 0.0044 26.3 0.21 0.31 0.46 0.69 1.02 1.26 0.0044 26.3 0.24 0.36 0.53 0.79 1.17 1.45 0.0060 49.0 0.46 0.69 1.02 1.50 2.23 2.760.0038 16.0 0.26 0.32 0.40 0.59 0.88 0.0049 30.0 0.24 0.35 0.52 0.77 1.13 1.41 0.0049 30.0 0.27 0.40 0.60 0.88 1.30 1.62 0.0065 53.3 0.50 0.75 1.10 1.63 2.42 2.990.0040 17.3 0.27 0.34 0.42 0.63 0.92 0.0054 32.0 0.26 0.38 0.57 0.84 1.25 1.55 0.0054 32.0 0.30 0.44 0.66 0.97 1.44 1.79 0.0073 59.6 0.57 0.84 1.24 1.83 2.71 3.350.0045 18.0 0.30 0.38 0.48 0.70 1.04 0.0060 35.4 0.29 0.43 0.63 0.94 1.39 1.72 0.0060 35.4 0.33 0.49 0.73 1.08 1.60 1.98 0.0075 61.5 0.58 0.86 1.27 1.87 2.78 3.440.0050 20.4 0.34 0.42 0.53 0.78 1.16 0.0065 40.4 0.31 0.46 0.69 1.02 1.50 1.87 0.0065 40.4 0.36 0.53 0.79 1.17 1.73 2.15 0.0090 73.3 0.70 1.03 1.53 2.26 3.34 4.140.0058 24.4 0.39 0.49 0.61 0.91 1.34 0.0068 44.5 0.33 0.48 0.72 1.06 1.57 1.95 0.0068 44.5 0.38 0.56 0.83 1.22 1.81 2.25 0.0093 76.0 0.74 1.08 1.58 2.31 3.46 4.280.0062 26.6 0.42 0.52 0.65 0.97 1.43 0.0070 46.6 0.34 0.50 0.74 1.09 1.62 2.01 0.0070 46.6 0.39 0.57 0.85 1.26 1.86 2.31 0.0096 78.2 0.74 1.10 1.62 2.40 3.56 4.410.0076 33.7 0.51 0.64 0.80 1.18 1.75 0.0090 58.7 0.43 0.64 0.95 1.41 2.08 2.58 0.0090 58.7 0.50 0.74 1.09 1.62 2.39 2.97 0.0110 90.0 0.85 1.26 1.86 2.75 4.08 5.060.0090 41.0 0.61 0.76 0.95 1.41 2.08 0.0120 81.0 0.58 0.86 1.27 1.87 2.77 3.45 0.0120 81.0 0.67 0.99 1.46 2.16 3.19 3.97 0.0130 106.5 1.01 1.49 2.20 3.25 4.82 5.970.0104 48.0 0.70 0.88 1.10 1.62 2.41 0.0170 117.0 0.82 1.21 1.80 2.66 3.93 4.36 0.0170 117.0 0.94 1.40 2.06 3.05 4.52 5.01 0.0140 115.0 1.08 1.60 2.36 3.50 5.18 6.42

TRI-HELICAL CELLCHART #11

PYRAMID CELLCHART #12 QUADRANGULAR CELLCHART #13 QUADRANGULAR CHANNELED CELLCHART #14 TRI-HELICAL CELLCHART #15

QUADRANGULAR CHANNELED CELLCHART #6

5% SOLIDS

15% SOLIDS

25% SOLIDS

35% SOLIDS

35% SOLIDS

45% SOLIDS

50% SOLIDSVOLUME 5%

SOLIDS15%

SOLIDS25%

SOLIDS45%

SOLIDS50%

SOLIDS CELL DEPTH5% SOLIDS

15% SOLIDS

25% SOLIDS

35% SOLIDS

50% SOLIDS CELL DEPTH VOLUME15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSCELL

DEPTH VOLUME 5% SOLIDS

15% SOLIDS

25% SOLIDS

35% SOLIDS

45% SOLIDS

CELL DEPTH VOLUME 5%

SOLIDS

35% SOLIDS

45% SOLIDS

50% SOLIDS

OFFSET GRAVURE OFFSET GRAVURE OFFSET GRAVURE OFFSET GRAVURE

VOLUME 5% SOLIDS

15% SOLIDS

25% SOLIDS

45% SOLIDS

50% SOLIDS CELL DEPTH5%

SOLIDS15%

SOLIDS25%

SOLIDS35%

SOLIDS50%

SOLIDS CELL DEPTH VOLUME15% SOLIDS

25% SOLIDS

35% SOLIDS

45% SOLIDS

CELL DEPTH VOLUME 5%

SOLIDS15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSCELL

DEPTH VOLUME 5% SOLIDS

PYRAMID CELLCHART #8 QUADRANGULAR CELLCHART #9 QUADRANGULAR CHANNELED CELLCHART #10

35% SOLIDS

45% SOLIDSCELL DEPTH5%

SOLIDS15%

SOLIDS25%

SOLIDS35%

SOLIDS50%

SOLIDS

DIRECT REVERSE GRAVURE DIRECT REVERSE GRAVURE DIRECT REVERSE GRAVURE

VOLUME 5% SOLIDS

15% SOLIDS

25% SOLIDS

45% SOLIDS

50% SOLIDS

50% SOLIDS CELL DEPTH VOLUME15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSCELL

DEPTH VOLUME 5% SOLIDS

15% SOLIDS

25% SOLIDS

35% SOLIDS

45% SOLIDS

CELL DEPTH VOLUME 5%

SOLIDS

TRI-HELICAL CELLCHART #7

6. CHOOSE THE ROLL FROM ANY VENDOR CHART THAT MATCHES THE VOLUME AND CELL TYPE.

DIRECT FORWARD GRAVURE DIRECT FORWARD GRAVURE DIRECT FORWARD GRAVUREPYRAMID CELLCHART #4 QUADRANGULAR CELLCHART #5

2. DETERMINE TYPE OF GRAVURE COATER3. DETERMINE TYPE OF GRAVURE CELL4. FIND THE DESIRED COATWEIGHT IN THE CHART

5. TRACE THAT ROLL OVER TO THE VOLUME IN THE SAME CHART

45% SOLIDS

50% SOLIDS

NOTE: THIS IS FOR CHROME PLATED GRAVURE ROLLS ONLY !1. DETERMINE SOLIDS

50% SOLIDS NUMBER CELL DEPTH VOLUME15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSNUMBER CELL DEPTH VOLUME 5%

SOLIDS15%

SOLIDS25%

SOLIDS35%

SOLIDS45%

SOLIDSNUMBER CELL DEPTH VOLUME 5%

SOLIDS

ENGRAVING COATING CHARTWEIGHT IN POUNDS DRY SOLIDS PER REAM - 432,000 SQUARE INCHES

WEIGHT OF MATERIAL 8 LBS. PER GALLON IN SOLUTION

PYRAMID CELLCHART #1 QUADRANGULAR CELLCHART #2 TRI-HELICAL CELLCHART #3

5

DIRECT GRAVURE

BACKING; LINESPEEDUndercut Required

BACKING/GRAVURE = 3/8” NIP

GRAVURE; 90% to 110% LINESPEED

USUALLY REQUIRES POST SMOOTHING

REVERSE GRAVURE

BACKING; LINESPEEDUndercut 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 LINESPEEDUndercut Required

OFFSET/GRAVURE = 3/8” NIP

GRAVURE; 10% to 25% OF LINESPEED

6

SMOOTH ROLL

BACKING; LINESPEEDNO 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

Transfer Roll Coater

Roll vs. Speed

Roll speed

Coa

twei

ght

1/2" nip

3/8" nip

3/4" nip

CHECKING NIPIMPRESSIONS

STEEL ROLL

LOAD

RUBBERCOVEREDROLL

FOOTPRINT

7

Coat Weight Curves

•Gravure Volume•Coating Solids

•Roll Speed•Coating Viscosity

GS

M

150%50% 100%Gravure Speed

ReverseGravure

GS

M

95% 100% 105%

Gravure Speed

ForwardGravure

10% 60% 100%Gravure Speed

GS

M

OffsetGravure

10% 100%

Pick-up Speed

GS

M

SmoothTransfer

Factors That Affect Coat Weight

•Nip Width

¼”

½”

¾”

COAT WEIGHT STABILITY•Effects of speed on coatweight

–Differential Offset Gravure - STABLE–Direct/Reverse Gravure - STABLE–Smooth Roll - UNSTABLE

GS

M

Line Speed

GravureSmooth Roll

YesYesNoYesAbility to Coat FoilAbility to Coat Foil

YesYesNoYesAbility to Coat Ability to Coat Printed FilmPrinted Film

NoYesYesYesRequires Undercut Requires Undercut Rubber RollRubber Roll

NoYesYesYesStable at All Line Stable at All Line SpeedsSpeeds

YesYesYesYesAbility to Coat Ability to Coat FilmFilm

NoYesYesYesAbility to Coat Ability to Coat PaperPaper

YesYesYesNoAbility to Adjust Ability to Adjust Coat WeightCoat Weight

Smooth Smooth RollRoll

Offset Offset GravureGravure

Reverse Reverse GravureGravure

Direct Direct GravureGravure

Coater Coater SelectionSelection

8

Thank You

PRESENTED BY

Lee A. OstnessProduct Manager Coating & Drying SystemsBlack Clawson Converting Machineryostnessl@bc-egan.com

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