Knife Over Roll Coating: What Does The Process Cover?

Curious about knife over roll coating? At Conversion Technologies International, we understand why. It’s a great option for many companies. But there are a few things we recommend learning about before you commit to this process…

How does knife over roll coating work?

Knife over roll coating involves spreading the coating over a substrate, rather than pouring or brushing it. The coating spreads between a stationary knife and a backing roll. We pair the titular knife and roll in order to maintain the precision of the coated layer. While other processes can produce an uneven coating with excess solution, blade coating prevents that. While we coat the substrate, the blade scrapes away excess. This also ensures less waste, and, in the long term, better cost-efficiency. The less solution you throw away, the more money you save.

The question with most adhesive coating methods is: How do you maintain the coating’s thickness? An uneven layer is not only aesthetically displeasing, but potentially weak and prone to wear and tear. The great thing about knife over roll coating is that it’s actually quite simple. The gap between the knife and the roll controls the solution’s viscosity, and therefore the layer’s thickness. You can easily make adjustments to that gap, thus ensuring you have control over the coating layer.

We can use knife over roll coating for multiple purposes. Typically, we turn to this method to create a topcoat. However, we might also select it when working with pressure sensitive solutions. Other applications include:

—heat-activated coatings
—solvent-activated coatings
—latex
—primers
—plastisols
—barriers

Generally speaking, this process doesn’t take much time compared to alternatives. It’s also relatively easy to alter as needed. But nonetheless, it’s important that you know exactly what you’re doing. Alternatively, you could work with a third party manufacturer to handle your processing needs. While some business owners are understandably nervous about outsourcing at first, it can be a great option as you refine and expand your company.

What are the benefits of knife over rolling coating?

There are so many benefits to choosing knife over roll coating. As with any process, the degree to which this one works for you will depend in part on your business’s specific needs. However, if you’re looking for a flexible, easily customizable coating method, this approach to industrial roll coating could be perfect. Some of the key benefits include:

—Less stress. Because this process is relatively adjustable, allowing you a great deal of control, it’s less stress-inducing than other methods. This is incredibly beneficial, especially as you grow your business.
—Customization. As we mentioned above, you can adjust your approach (and therefore your results) without great issue. You can rearrange the gap between the knife and roll, changing the thickness of the coating. This makes this system easier to apply to different types of projects. Even when you’re working with a third party manufacturer, it simplifies the process. You don’t have to shift between different strategies. Instead, you can stick to knife over roll coating throughout!
—Speed. You can coat a wide range of products quickly and efficiently. At the same time, you’ll maintain quality control and consistency. This is especially important as you scale up.
—Affordability. You don’t have to worry about over-spending when you work with knife over roll coating machine. This is one of the more cost-efficient coating approaches. And it can become even more affordable when you work with a great third party manufacturer.

What company provides roll coating services?

If you’re looking for a company to provide roll coating services, look no further than CTI! As a third party manufacturer, we offer a wide variety of services—coating included. While that covers more conventional coating projects, we’re also flexible enough to explore new methods as needed. One client of ours worked within the wind energy spaces, and as such had very specific requirements, including an adhesive coating for flexible, lightweight fiberglass. While executing this project wasn’t easy and required trial and error, we did so on time exceeding our client’s expectations.

That’s one of the benefits of working with an experienced third party. If a product isn’t exactly up to your expectations initially, we can help get it to where it needs to be. We have not only the equipment and facilities, but the expertise necessary to work with even the more challenging cases. 

Frequently Asked Questions

Still not certain about how to proceed? Here are some frequently asked questions about knife over roll and coating, and how it relates to outsourced processing.

Do I have to provide equipment to a third party manufacturer?

A third party manufacturer provides all the equipment, as well as the labor and facilities. You don’t have to worry about investing in machinery or parts like a coating head or roller. So, you don’t have to provide knife over roll coating equipment. That’s up to us!

What’s the difference between contract manufacturing and toll manufacturing?

As you explore third party manufacturing, you’ll probably come across two options: contract manufacturing and toll manufacturing. A contract manufacturer handles the entire process from beginning to end. You make an agreement, and they handle the processes. A toll manufacturer, conversely, handles the processing, but you provide the raw materials.

Is knife over roll processing the best coating method on the market?

While it’s one of the best methods, it won’t be the best method for every business. You should explore several options and consult with the experts before making a final decision.

Speaking of…

What do I do next?

The experts are waiting to talk to you right now! Call CTI at 419-924-5566 right now or contact us here. Let’s begin!