Understanding Web Coating Technologies and What They Offer

When exploring coating processes, it’s normal to be overwhelmed at first. The great thing is that you have plenty of techniques to choose from. You might need a little help in figuring out which one is right for your project. Today, we’re exploring just that—and paying particular attention to web coating technologies.

What is coating technology?

Coating technology covers a large array of techniques and processes. Many industries depend on coating processes on a manufacturing level. This is because coatings are protective. We use them to not only seal surfaces, but keep them from corroding over time. This means you’ll have a lot less to worry about when it comes to damage (and breakdowns). Plus, your products inevitably last longer. The longer your products last, the less often you’ll have to replace them. You’re saving not only time (in the form of efficiency) but money as well.

Coatings come in many different forms. Generally speaking, coatings protect against broad corrosion, as well as:

• Chemical degradation
• Structural degradation
• Fouling
• Biofouling
• Extreme temperatures
• Humidity
• UV radiation
• Regular wear and tear—whether this causes internal damage or aesthetic damage. Or both!

What are the different types of coating technologies?

As we said earlier, coating covers a number of different techniques:

Roll coating. This uses a rotating applicator roll to apply the coating to a substrate. Typically, we utilize this technique in either a direct or reverse motion.

Dip coating. You may see this referred to as immersion coating. Noted for its affordability, this technique works on a variety of different shapes. It’s also fairly easy to alter the thickness of the coating. Versatility makes this quite popular among manufacturers.

Flow coating. With flow coating (also known as float coating) we’re able to coat products too big to cover through dip coating. This technique uses less coating material, and we can automate it as needed.

Web coating. This coating technique offers some unique features. It allows for a continuous application—but in this case, we’re applying the coating to a thin, flexible web material.

Today, we’re paying special attention to the last technique—web coating. Let’s dive in!

How do web coating technologies work in particular?

We can apply web coating to many different surfaces. However, the most common you’ll see are paper, metal, and plastic. The vast differences between these surfaces demonstrates just how broadly we can use web coating technologies. It’s no wonder web coating has become so much more popular in recent years, overtaking some of its rivals.

Generally speaking, web coating is one of the more affordable coating options, adding to its benefits. It’s also more efficient. As such, you’re spending less time (and less money) on web coating. This comes in handy as you scale production. As you go, you’ll need to make processes as smooth as possible—with expansion in mind. With web coating, it’s much easier to grow your business, add new orders, and deliver more product.

Of course, another aspect to consider when scaling up is outsourcing to a third-party manufacturer. In this day and age, many business owners choose to outsource their third-party industrial manufacturing needs. A contract manufacturer, for example, may be able to offer multiple types of coating methods. And for that matter, they’ll offer it with a level of expertise that ensures consistent, timely results.

One thing you might want to ask a third-party manufacturer about? The different types of coaters.

What types of coaters are available?

Just as there are different web coating techniques available, there are different types of coaters. Coaters act as an application component. The type of coater you work with is dependent on the coating method needed for each project.

Some of the key coaters include:

• Rod coaters. These are what we call “rigid metering device coaters”. Although there is more than one kind of rigid metering device coater, rod coaters have a specialized cylindrical design. Rather than focusing on the blade, rod coaters center the base sheet. Furthermore, the rod rotates against the web while coating. This cuts down on streaking and scratching.
• Blade coaters. The blade coater results in the smoothest possible surface. However, if not administered by correctly, it also places more stress on the surface. Sometimes, this results in in web breaks, which cuts the coating machines short. Additionally, it’s more likely to cause scratching and streaking. Thus, it is critical to have an experienced operator overseeing this method.
• Curtain coaters. A curtain coater features a gap between two conveyors. They coat the substrate with a curtain of fluid, with the speed of the conveyors and the solution’s flow rate determining the coating’s thickness.
• Web coaters. We’ve already covered this for the most part. But to get a little more specific, a web coater unrolls the web and passes it over the surface in question. It then re-rolls it at a high speed, resulting in the final coating.
• Gravure roll coaters. In this case, the roll coater is a pick-up roll with specific cell parameters. It pairs with an offset roll, printing a metered coating fluid film onto a sheet of paper. This creates a coating that follows the contours of the surface—making gravure coating a method we use for more specialized orders.

In conclusion:

Now that you know a bit more about coating technologies, it’s time to go more in depth. The best way to do that is by contacting CTI. Reach out here or give us a call at 419-924-5566. We have the answers you need!