Web Coating Blog

AIMCAL Fall Technical Conference October 2008

AIMCAL Fall Technical Conference
October 2008
Edward Cohen
The AIMCAL Fall Technical Meeting was help in October in Myrtle Beach,
NC. It provided a forum for the exchange of Information between
technical personnel in the web coating Industry. Technical papers were
presented in four sessions as follows:
• Environmental Responsiveness
• Web Coating & Laminating
• Vacuum Web Coating
• EmergingT echnologies
• Advances in Web Coating Technology
In addition there were table to exhibits, which also provide an
opportunity for additional technical discussions.

I found all of the presentations were useful and relevant to the technology of importance
to the Converting Industry. While the Coating process is sold, there is
still a a lrge amont of new technology that is being developed.

Wide ranges of topics were discussed, energy concerns, coating methods, slitting,
barrier layers, Coating hardware etc.

The following are the titles and a summary of some of the key
presentation. Details of the papers and contact information can be
found in the Conference Proceedings available from AIMCAL.

A Paradigm Shift In Knife Holder Slitting Technology
David Rumson
Sigmala, USA

Conventional slitting systems, consisting of mechanically
mounted and pneumatically activated knife holders (Mech/Pneu) have been
in existence for approximately 60 years. Although shear knife holder
and positioning systems have advanced during this time, there are some
basic operating requirements that remain limited in efficiency and
usefulness relative to today’s computer controlling capabilities. This
paper will present a basic overview of the physical operating
differences of Mech/Pneu holders and Servo Motor-Computer Controlled
holders (Serv/Com).

Application Of Surface Analysis For Root Cause Failure Analysis
David Cole
Evans Analytical Group

X-ray Photoelectron Spectroscopy (XPS) and Time-of-Flight Secondary
Ion Mass Spectrometry (TOF-SIMS) are valuable analytical techniques in
determining the rooot cause of failure in multilayer films.

Breaking Thru A Paradigm:New Technology For Coating And Laminating
Mike Budai
TW Dynatec

The purpose of this presentation is to break thru a paradigm in
laminating nonwovens, textiles, and composites. This paper will present is to
introduce the latest technologies in coating and laminating utilizing
hot melt polymers.

Reducing Changeover Time on a Coating Line,
Larry Gogolin
Gogolin & Associates

This paper will cover the steps to consider in establishing a reduction in the changeover time. It will look at planning, data collection, analysis and what to do with this
information.

Optimizing Mix Performance”
Ken McCarthy

This paper presents a discussion of mixing time and its importance to
coating operations.

Stay Ahead of Static Problems in Film Conveyance
Kelly Robinson,
Electrostatic Answers LLC

Demands for static control in film conveyance are increasing because
products are more complex and sensitive to static discharges. Four keys
to staying ahead of static problems in web conveyance are presented T
he implementation of these four recommendations for a typical coating
operation is presented.

Primerless Heat Seal Coatings for Film Substrates
Virginia Cushing &Robin Cooper
Michelman

This paper presents a single pass, aqueous heat seal coating which
exhibits excellent hot tack and a wider operating window as compared to
conventional heat seal coatings and common extruded sealants.

Increasing Energy Efficiency in the Web Coating Process
Edward Cohen, Dan Bemi Megtec

This paper focuses on reducing energy consumption, by modifying the
overall coating process and to utilizie renewable resources in their
production in order to remain competitive in this climate of rising
energy costs.

Intelligent Process Cooling: Saving Money, Protecting the
Environment
& Curing Process Headaches
Steven Petrakis
Frigel

Process cooling with ambient air, closed loop cooling systems can save
up to 25% on energy and water consumption in addition to eliminating chemical
evaporation and the disposal of contaminated waste water.

Nanoparticulate Barrier Films and Gas Permeation Measurement Techniques
for Thin Film Solar and Display Applications
Senthil Ramadas*, Shwe Zin Ma, Mark Auch, Chua Soo Jin
Institute of Materials Research and Engineering.

This paper presents innovative approach to resolving the ‘pore effect’
by literally plugging the defects in the barrier oxide films using
nanoparticles. The nanoparticles used in the barrier stack have a dual
function – not only sealing the defects but also reacts with moisture
and oxygen. The result is an achievement of moisture barrier
performance of better than 10-6g/m2/day that surpasses the ideal
requirements needed for flexible applications,

Effective Networking, A Path Through The Information Overload

                        Effective Networking, A Path Through The Information Overload
                                            Edward Cohen

Even though we live on large planet, with large physical dimension (a Volume of 1.0832073_1012 km_ and a  Mass of 5.9736_1024 kg); technologies such as the Internet, Information Sciences, World Wide Web, rapid digital communications ,easily accessible databases and search engines have made it a very small world. It now possible to instantly communicate with persons all over the world and to obtain technical information from most countries, businesses and Universities.

WEB COATING AND DRYING PROCESS TECHNOLOGY

The AIMCAl  Converting School is sponsoring  a course on Web Coating and Drying Proces Technology. The detaieled course outline is below. For more information and to register, see www.AIMCAL.org

                    WEB COATING AND DRYING PROCESS TECHNOLOGY
                    Edward Cohen, Ph. D Edward Cohen Consulting, Inc.
                E. J. (Ted) Light foot, Ph. D Dupont Fluoroproducts

CEMA Coating & Laminating Fundamentals

AIMCAl & CEMA will be sponsoring a Seminar on Coating & Laminating. The schedule is below. For more information and to register go to
        www.AIMCAL.ORG

Continuing Education Courses.

The Association of Industrial Metallizers, Coaters and Laminators (AIMCAL) is sponsoring several continuing education courses in Converting Process Technology in 2008.

Response to Question on Laboratory Coater Vendors

Response to Question on Laboratory Coater Vendors
Edward Cohen

IN response the question on the web coating blog, about sources for laboratory coaters. There are several companies that specialize in laboratory coating machines. The contact information is listed below

Slot Die Coating

                                                        Slot Die Coating
                                                        Douglas Darrow
                                                        Cloeren Inc.
                                                        ddarrow@cloeren.com
                                                                            715-552-7421

A question often asked is: ‘Why should I consider a Slot Die, instead of the coating method that I am currently using?’  There are a multitude of reasons, most of which are well known to people who have been in the coating business. 

One Thing to Optimize Process

A question that is often asked about the Web Coating Process is “ What are the one or two most critical areas of the process that I should concentrate on to obtain a coated product with high quality and low cost?”. A possible basis for this question can be found in an interchange in the 1991 movie “City Slickers”, between Billy Crystal and Jack Palance

Defect Reduction Process: What’s in a name

One of the most important step steps in an effective defect reduction process in the web coater is the accurate naming of the defect. This name must be unique for a defect, unambiguous and interpreted in the same way by all who use the name. Naming is usually an easy straightforward process because most areas of science have standard naming conventions. For example, there are standard names for organic chemicals, which are used by all scientists. These are issued by the International Union of Pure and Applied Chemistry. Thus all chemical compounds can be unambiguously named.  Similarly the disciplines of Chemical Engineering, Electrical Engineering and Physics all have standard naming conventions.

ROLE OF THE SUBSTRATE PART !

The substrate used in the coating process is a key element in the successful operation of a web coating process.  The substrate is the carrier of the active coating layer. The effect of the substrate on the coating process needs to be understood, optimized and controlled to insure quality and cost. Web and support are also terms used to refer to the substrate.

The major areas of technical importance for the substrate are:

    • Substrate structure
    • Surface Properties treatments and coatbility
    • Mechanical Properties 
    • Defects Arising from Substrate
    • Substrate Flatness   
    • Specification of Substrate   
    • Substrate Manufacturing
    • Substrate Roll winding & unwinding
    • Substrate web handling in coating machine