Transcript In-Line Coating Application
In-Line Coating Application
Presented by: Thies Janczek
27/04/2020
Content
Introduction Technology Advantages Economical Technological Current Applications Summary Customer Presentation COCASO 1
Introduction Laminated card
27/04/2020 Overlay Print
Core Print Material (PVC) in thicknesses of 200
Overlay
multi color litho, UV curing
split core mono core
Customer Presentation COCASO 2
Introduction Laminated card
Overlay Print The printing is creating a layer between the PVC (or other thermoplastics), therefore an adhesive is mandatory for a good lamination result.
Today this adhesive is applyed On the overlay in web coating by the material supplier.
On the print sheet, in screen printing by the card manufacturer Alternatively: Apply with the coater on the litho press!
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Technology Flexo Coater on litho press
Typical Anilox system of the OEMs Tresu, DK Harris and Bruno, USA Typically used for top coats (< 20% utilization at most card manufacturer) COCASO 4 Customer Presentation
Technology Flexo Coater on litho press
Scheme of a flexo coater.
Advantage in a thicker material layer that can be transferred.
Anilox characteristics should be carrying a volume of >20bcm
ADHESION IS A FUNCTION OF ADHESIVE THICKNESS AND UNIFORMITY
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Technology Water based on a litho press
Main point: The coating has to be dry as it is delivered to the stack.
Water based adhesive dries by air flow across the coated surface.
Air knife – low investment, easy to achieve.
Blow units are standard in many machines.
Transparent coating does not interfere with the final curing of colors.
COCASO 6 Customer Presentation
Technology Dry versus Wet adhesive
Overlay Printsheet
Hard meets Hard The hard adhesive is pressed onto the cured litho colors in the laminating press. As the temperature increases the adhesive melts, flows and performs the bond to color and substrate.
Liquid meets Soft The liquid adhesive is applied onto the pre-cured litho colors. Instant wetting of the whole surface and a leveling out effect. Good penetration into micro crevices and voids increase even the bond between UV color and substrate COCASO 7 27/04/2020 Customer Presentation
Technology Adhesion after Lamination
Overlay
Effect exaggerated
Printsheet
Bond to inconsistent print sheet surface Need for good flow properties cause distortion effects Hot melt melt-temp does not change 27/04/2020 Customer Presentation Bond to consistent overlay surface Only low flow properties are needed Heat started x-linking raise melt-temp permanent bond COCASO 8
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Advantages - Ecological
Material cost saving Just uncoated overlay needed Artwork with low ink coverage w/o adhesive, i.e. just text artworks w/o bleeding over the card edge do not need adhesive.
Higher utilization of Equipment Longer value-added chain Pigmented adhesive for special effect w/o additional silk screen step COCASO 9 Customer Presentation
Advantages - Ecological
Example calculation per laminate: Conditions (most probable) 50µm standard PVC Overlay 5µm coating thickness 48 cards per sheet (size 620x520mm) 27/04/2020
SAVE more than 17 cent per laminate
Customer Presentation COCASO 10
Advantages - Calculate your numbers
Comparisson In-Line coating vs. Coated Overlay
(considered materials are the overlay and the adhesive coating)
PLEASE MOUSECLICK TO ENTER YOUR VALUES INPUT
Overlay width [mm] Overlay length [mm] Overlay thickness [µm] Overlay density [g/cm³] Cards per sheet OV coating [g/m²] 520 620 50 1,33 48 5
CALCULATIONS
sheet weight uncoated [g] sheet weight coated [g] Cost per sheet for Coated Overlay In-Line coating 21,44 23,05 0,1521 € 0,0665 € Cost per laminate OV price uncoated €/kg OV price coated €/kg 3,10 € 6,60 € Coated Overlay In-Line coating 0,3043 € 0,1330 € 1,07
SAVINGS
WINK density [g/cm³] WINK thickness [µm] (wet appr. 2xdry) WINK cost €/kg (incl.shipment) 10 15,00 €
per LAMINATE per CARD 0,1713 € 0,0036 €
27/04/2020 Customer Presentation COCASO 11
Advantages - Technological
27/04/2020 Process under own control Utilization of existing Equipment Low investment for air knife (< € 5000) Neglect able process costs Higher bond strength Increased adhesion of the litho color to the substrate Environmental friendly material/process Customer Presentation COCASO 12
Advantages - Technological
27/04/2020 Decreasing lamination time and/or temperature When all interfaces are coated, e.g. mono core with inline adhesive coating or in split core one print sheet coated on the center side.
Increased output Better adhesive uniformity Overlay independent Customer Presentation COCASO 13
Current Application
27/04/2020 WINK Adhesive application on Litho presses with an Anilox coating station (OEM either TRESU or Harris & Bruno) Same WINK formulation for screen application is employed as a primer and as adhesive (back up solution) Pearl effect pigment dispersed in adhesive matrix for adding value to the cards Customer Presentation COCASO 14
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Scenario ROI on a stand alone coater
Simple calculation for an overview: Estimated invest: Saving per card: 130.000 € 0,36 €cent Annual production: 200 Mio cards
ROI is under 2 years (22 months)
COCASO 15 Customer Presentation
Summary
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On existing coating capacity very low investment.
High cost savings compared to other material/process options
Established process in the industry
High reliability, good process control, and high bond strength
Added-value chain for card producer
Customer Presentation COCASO 16
In-Line Coating Application
ANY QUESTIONS ?
CONTACT US !
COCASO – Thies Janczek – Moewenstrasse 5a – 24113 Molfsee – Germany Phone: +49-(0)4347-703526 – Email : [email protected]
www.cocaso.com
OR FUNCTIONAL MATERIALS INC. – Josef Feldman – 150 Route 17 - Sloatsburg, NY 10974 USA – Phone: +1-845-753-6000 – Email: [email protected]
www.functionalmaterials.com
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