The document discusses innovations and trends in coating technology for graphic art. It describes different types of coatings categorized by their formulation (e.g. solvent-based, water-based), application process (e.g. gravure, flexo), and end use. New trends include UV-curable coatings that provide special visual effects like texture, soft-feel, and thermochromic properties. The document also discusses opportunities for aqueous and solvent-based coatings, as well as growth in the Asia-Pacific coating market led by China, India, Japan, and Korea.

1. Innovations in Coating
Technology for Graphic Art
By :
Adesh Katariya
Manager- R&D, Tirupati Inks Ltd
plast.adesh@gmail.com

2. Coating-General
The adding of a clear layer
on to
a Substrate (printed or unprinted)
to
protect 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

3. Functions of Coatings
Typical expectations of coatings
Easy application and cost effectiveness
Environmental friendliness
Uniform film formation
Non-Toxic
Durability
3
Appearance Protection

4. Types of Coating, As per Formulation
 Solvent Based Coatings
 Water based(Aqueous) coatings
 Oil Base Coatings
 Radiation curable Coatings ( UV / EB)
4

5. Types of Coating, As per Application process
 Gravure Application coating
 Anilox( or Flexo ) Coatings
 Roller-coater Coatings
 Offset Coatings
 Screen Coatings
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6. Types of Coating , as per end use
1. OPV( Over Print Varnishes)
o Packaging
o Commercial
2. Functional Coatings
o Primers
o HSL
o Barrier Coatings
6

7. 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
Radiatio
n Curing
Photo-Initiation 2 1 1 1 4
Electron Initiation 1 1 1 1 3
Paste Oil Based 1 1 1 1 1

8. Performance, Cost and Risk comparison of Coatings
8 Lighter to Dark/ 1 to 5 :Low to High
Performance Cost Risk ( Health)
Liquid Ink
Solvent Based 3 3 5
Water Based 2 1 1
Radiation
Curing
Photo-
Initiation
4 5 4
Electron
Initiation
5 4 3
Paste Oil Based 1 2 2

9. 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
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10. 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
Coating
o Resulting less ink consumption in printing
o Smooth, high Lusture surface of metallized paper.
Standard Paper Calendared Paper Coated Paper

11. Blister coating
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Coating applied on Board
and then heat sealed
with PVC Packages.

12. Barrier coatings for Clear high Barrier
laminates
1. Barrier coatings to increase Oxygen barrier properties
of BOPP
2. Barrier coatings to increase Moisture and gas barrier
properties of PET.
12

13. Water Repellent coatings
Special aqueous coating for Water Repellency of
corrugation board after coating
Main aim : To convert maximum wooden/plastic packing
into recyclable corrugation packing.
Coated Un-coated
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14. 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
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15. 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 .
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16. 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
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17. 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.
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18. New Trends in Energy Curable Coatings
Special effect UV Coatings
1. Texture coating
2. Haptic(Soft feel) coatings
3. Sand effect coatings
4. Glitter effect coatings
5. Emboss Coatings
6. Spot UV Coatings
7. Sparkles UV Coating
8. Thermochromic UV Coatings
9. Photo-luminescent Coatings
10.Pearl Effect UV Coatings
11.Wrinkle coatings
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19. 1(A) Texture coatings: Orange Peel effect coatings
 Special Screen UV Coating cured to a textured finish
that looks like orange skin
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20. 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
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21. 2. UV Haptic (Soft-touch)
coatings
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 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.

22. 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

23. 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

24. 4.Glitter effect coatings:
 Screen UV Coating contains small holographic bits of
glitter .
 The effect is most pronounced over dark colors.
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25. 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

26. 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

27. 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

28. 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.
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29. 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 from
the friction caused by rubbing causes the coating to
change colors.
 Beer producers have used this technology to indicate
when their product is chilled.
 Thermochromic coatings typically are available in various
colors and temperature ranges (4o C and 37o C).
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Same coating looks
At 15 DC At 40 DC
White Orange

30. 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

31. 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/
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32. 10. Pearlescent UV Coatings
 Pearl additives are mixed with gloss UV coating to give this
coating a luxurious appearance.
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33. 11. Wrinkle effect UV Coating
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 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.

34. New Trends in Energy Curable Coatings
34
Special Application UV Coatings
1. UV Coating for PVC Profiles
2. Optical Fiber UV Coatings
3. Anti-fog UV coating
4. Release Coatings
5. Hot Foil Stampable UV Coatings
6. Holographic UV coating
7. UV LED Curable coatings
8. EB Curable coatings

35. 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 are
o PVC door/window profile
o Ceiling panel/wall panel
o Matt /glossy laminate etc.
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36. 2. Optical Fiber UV Coatings
 Optical fibers are so designed that their transmission properties will not
change despite fluctuations in the temperature and humidity of their
environment or the passage of time, and in this requirement can be
fulfill 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.
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37. 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.
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38. 5. water-resistant anti-fog UV coating on
plastic material
A 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.
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39. .
Applications
o Commercial complexes outer body
o Safety Glasses or Visors
o Electronics Protection Covers
o Advertisement Signage
o Storefront Windows/Doors
Desired Features
o Permanent Anti-Fog Coating Treatment for Plastic Substrates
o Washable Coating ( Good detergent/Acid rain Resistance)
o Good Scratch and Impact Resistance
o Simple Wet Chemical Application Methods and Fast Curing Process
o Long Coating Solution Shelf Life with Stable Chemical and Physical Properties
39

40. 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.
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41. 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.
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42. 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
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43. 8. Nail-gel UV LED Coatings
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 UV LED Curable Nail gels coating with textured glass
flakes

44. 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
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45. .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)
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46. 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
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47. 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
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48. 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
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49. 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
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50. 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 driver
shall be
Quality
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51. THANK YOU