Challenging Developments in Coating and Printing Technologies

© KROENERT GmbH & Co KG 5th SPECIALITY FILMS AND FLEXIBLE PACKAGING GLOBAL SUMMIT 2016 in Mumbai
Challenging developments in coating and printing for
increasing the markets for films and foils
5th SPECIALITY FILMS AND FLEXIBLE PACKAGING GLOBAL SUMMIT – 2016
21st – 22nd September, Grand Hyatt, Mumbai, India

KROENERT introduction
Self-metered versus pre-metered coating and printing technologies
Application samples
Coating line concepts
Summary
2
Agenda

Company information
- Founded 1903
- 260 employee
- 80 Mio turnover
- Certified according ISO 9001
Machines for roll to roll processing
 Paper
 Films
 Metal foils
 Laminates
 Textiles
Application of coating media
 diluted in water/solvents
 100% solid compounds
 waxes, paraffin's, hotmelts
Coating media, e.g.
 lacquers, adhesives, silicones, PVdC
 resins, polymers, pigments
3
Product range
KROENERT

4
Complete Coating Lines
 Design, Engineering, Production
Erection and Commissioning
Coating Machines
 Multi Roller Coater, Gravure Coater, MPG
Die Coater
Unwinding and Rewinding Systems
 Shafted and Shaftless, Automatic Splicing
Roll Handling
Dryers
 Convection Driers; oil, gas or steam heated
with rollers, belts or flotation nozzles
Product range
KROENERT

High performance of the coating necessary:
- Coating absent of defects
- Cross-Web Distribution less than +/-1%
- Wet thickness less than 1 µm – dry less than 100 nm
- Coating thickness must remain constant over 24h of production
- Printing texture with highest resolution
Which coating
and printing
technique is
suitable???
Requirements for precise printing & coating
5
Coating processing
In general

 Self-Metered-Coating means that the applied coating weight depends on the process => e.g. Dip-
Coating, Roller-Coating, Knife-Edge-Coating
 Pre-Metered-Coating means that the applied coating weight does NOT depend on the process =>
e.g. Slot-Die-Coating, Spray-Coating
Self-Metered Coating Techniques
Pre-Metered Coating Techniques
6
Coating processing
Self-metered versus pre-metered

Application weight in relation to machine speed
7
Coating processing
Self-metered versus pre-metered

Technology
• Smooth roller technology
• Definition of coating weight by gap between roller and roller speed
Viscosity range:
• 1 – 1.000 mPas
Coating weight range:
• Less than 0,1 g/m² up to max. 120 g/m² wet
Advantages
• Large variation of coating weight
Disadvantages
• Evaluation of coating weight depends on many different parameters
Usage Area
• Adhesive application
• Hotmelt application
• Lacquer application
Coating processing
Self-metered Smooth roller
8
Smooth roller technology

Coating processing
Self-metered Smooth roller
9
Combination of commabar and roller application – indirect or direct
Realized customer project
in Russia
10 – 400 µm wet
Viscosity 1000 mPas– 1000 Pas

 Web-Tension-Mode
 Extrusion-Coating-Mode
 Bead-Coating-Mode
 Short-Curtain-Coating-Mode
 Long-Curtain-Coating-Mode
Distance
d = 0
d < h
d > 2 h
d ca. 1 cm
d > 1 cm
Slot-die technology characterized by:
- Capillary forces acting between slot-die and the substrate
- Distances between slot die and substrate of less than 200µm
- Very low wet film thicknesses (~ 1µm) is possible at substrate speeds of less than 50 m/min
Coating processing
Pre-metered Slot die
10
Slot die technology – coating window variation

 The calculation of coating windows helps to control the process
 The following parameters are important
- Fluid parameters (viscosity, surface tension)
- Process parameters (distance between slot die and substrate, wet film thickness, substrate
velocity)
- Lip length of the slot-die
Uw
∆P
Slot die technology – coating window for bead-coating
Width
Coating

B
Massflow

m

Velocity
Substrate

W
U
thickness
Wetfilm

h
Density


B
h
U
m W 


 

Coating processing
11

 High variety in coating weight
 High variety in viscosity behavior
Intermitted coating operation with slot die technology
Coating processing
12
 die for full size
 die for stripes
 intermittent die
 combinations

Coating processing
Pre-metered Curtain coating with slot die
13
1 slot die (SWC-Coater) 1 to 3 slot slide die (MWC-Coater)
Adhesive application for clear to clear label products
 High speed requested from 50 to 350 m/min and higher.
 Low viscosity behavior requested under 10 Pas.
 Usually for PSA hotmelts.
 Coating weight between 2 and 200 g/m².

Coating technology with MPG
• Definition of coating weight by
• Engraved roller design
• Squeezing technology
• Pressure in case of using a pressure chamber for
coating material supply to roller
Viscosity range:
• > 1 – 1.200 mPas
Coating weight range:
• Less than 1 g/m² up to max. 120 g/m² wet
Advantages
• Precise definition of coating weight
2
3 1
alternative:
positive adjust-
ment
negative
adjustment
of blade
Working principles of the MPG
apprx. 80 mbar
low over filling high over filling
after media transfer
apprx. 350 mbar
Coating processing
Pre-metered Gravure roller coating
14
Gravure roller technology

Coating processing
15
Gravure roller technology in different variation
Reverse, direct Kiss Coating Kiss Coating and
structured roll
(top coat)
Reverse – Gravure - Coating with pressurized doctor chamber MPG
 Engraved ceramic coated roll
 Ceramic blade
 Pressurized doctor chamber in stainless steel
 Sleeve technique

Adhesive application with gravure roller system and MPG
Start-up
 Application of a closed and constant adhesive film.
 Substrate paper and PET with silicone surface.
 Water based adhesive.
 Target 8 g/m² dry with 20 % solid content fluid.
Realized tests
 Engraved roller technology.
 Reverse roller application.
 Coating chemistry supply with pressure chamber MPG.
Results
 No foaming of coating chemistry.
 Reaching of a closed and very constant film.
 Coating thickness 8 g/m² at 30 m/min.
16
Coating processing

Laser engraved flexo printing sleeves
 Defined high precise flexo-printing technology with
changeable printing sleeves.
 Precise coating material feeding with engraved
rollers.
 Laser pattern of the sleeves for highest resolution.
Coating processing
17
Flexo Printing

Coating processing
18
Printing – combination of gravure and screen printing with register
gravure coating / reverse mode
G:/TBMBed/07-Bilder/Vorträge/Dr.Neumann
• Lines per centimeter
• ratio
• Volume , ml/cm²
• depth, µm
web material
backing roller (rubber)
gravure roller (steel)
gravure geometry
- different angle
speed
trihelical
lines
V V
br gr
<
Precise printing
processes
Compact pattern up to
very fine and thin lines
Register steering
Layer 1 – gravure roller
printing
Layer 2 – screen printing

Application for film coating
Product variation
19
 Packaging application
 Protecting of food and medical products
 Transport packaging (electronic products)
 Printed Electronic
 Organic and thin film photovoltaic
 Sensor technology, RFID antenna …
 NFC-labels
 Protective Films
 Heat and light reflective films
 Encapsulation of electronic devices like OPV
and OLED
 Optical Films
 Electro chrome foils
 Reflective coating …
Orafol.com

PVdC for food packaging:
 2 sec curing time is usually
sufficient for low film thickness.
 Haze influence is also coming
from the curing process.
 Water evaporation and melting
of the polymers for film
formation.
 Coating weight 1 – 30 g/m³
 Speed up-to 600 m/min
PVdC for medical applications:
 barrier, sealing properties,
 printability defined by the polymer
quality,
 avoid blocking,
 Coating weight 60 - 140 g/m²
 Speed usually max. 150 m/min
Application Packaging
Barrier film application
20

Applications for transparent barrier layers
Application Packaging
Barrier film application
21
PET
Waste and cost reduction
• Aluminum replacement
• Substrate thickness reduction
• Simplify of laminated structures
• Used of recycled of materials (e.g. PET)
• Recycling of mono-materials easier to realize
• Transparent barrier layers
• Application of heat seal lacquer
• Application of primer for coating and printing
processes

Printed electronic
 Labels with information transfer
by Near Field Communication
(NFC)
 Electro luminescent layers
 Electro chrome layers like used
for the window shades in the
Dreamliner B787
 Foldable electronic magazines
and displays
 Printed boards and RFID-antenna
 Printed sensors
 Organic solar cells
www.boeing.de
Application Printed Electronic
Film coating and printing
22

Applications OPV
23
Source of information: information exchange during the OE-A meeting in May 2015, pictures: Andrea Glawe
• Printing of OPV-cells with gravure roller technology from
Belectric
• Inverted solar cell
• Efficiency 3 – 4 %
• Enough energy production to produce the energy of the
German pavilion
Gravure-roller for organic PV

Applications OCA
24
 Display protective tapes with self-adhesive layers
 Easy clean / anti-smudge coating layers
 PU, acrylic or epoxy adhesive (OCA) and contrast
film, self-adhering, clean removal (60 – 120 µm
thickness usually)
 Application of optically clear acrylic adhesive on 50
µm PP protective film (25 – 50 µm thickness
usually)
 Application of printed conductive materials
 Application of anti-reflective layers
 Self-adhesion foam tape in between the different
functional layers
 Any kind of coated tapes
 Bonding films
 Any layer for the battery (anode, cathode, separator
membrane)
Functional films and layers
www.3M.com

Applications Membranes
25
Development for ceramic separator membrane
• Tension very critical because of the sensitive membrane.
• Corona treatment very important to improve the surface
tension.
• Substrate spreading quite critical to avoid curling.
• Thermal relaxing of the film for a better stability tested.
• Critical slurry parameters because of the silicate mixture
and sedimentation fear of the slurry.
• Roller application – critical because of the abrasive
particles in the coating medium.
• Slot die tests resulted in the optimized technology.

Configuration for silicone release liner and adhesive coating
RECO
26

Configuration for film functionalization
RECO
27

Configuration for barrier application with PVDC
RECO
28

Configuration for Tape development
LabCo
29
Special application:
 Clean room class 1000
 Different coating methods
 Roller technology direct and indirect
 Gravure coating direct and indirect
 Commabar technology
 Slot die and curtain coating
 Clean room dryer
 Winding technology – 4 unwinder and 3 rewinder
 Lamination with temperature steerable rollers
 Web cleaning
High performance coating line in a modern
Technology Center
Coating line installed in clean room class 1000

Configuration for the production of OPV
LabCo
30
5 coating units with register
control – CSEM Brazil
Development with Fraunhofer ISE

Thinfilm Sweden
Configuration for printed sensors
LabCo
31
NFC technology for labels

Hotmelt coating and lamination line
PAK 610
32
- for hotmelts, wax, paraffin and epoxy resin application
- temperatures up-to 200 °C
- roller application

Benefit for our customers:
 Test runs under production conditions
with various coating methods
 Process optimization
 Process development
Purpose for KROENERT:
 Optimization of existing processes and
development of new technologies
 Determination of guaranteed process
specifications
 Development of process expertise (from
know-how to know-why)
The Technology Center
… for your support and common development
33

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