Coverings and combinations

4 May 2006




Eco friendly and a space saver

Soma Engineering claims its new Lamiflex E solvent-free laminator has a compact design that is both cost effective and cost saving, as well as benefiting the environment.

While the Czech company’s original Lamiflex S concept has been extended to the new design using many of the same components, instead of the original three-stand model, the new E machine utilizes a two-stand format. The footprint has been shortened by 1,700mm to free-up floor space in the factory without compromising the quality and productivity of the laminator.

The new system operates at up to 350m/min and can process a wide range of substrates including films, foil and paper. The drives for the unwind, machine rollers and rewind are all AC servomotors to optimize accuracy and control. The operator uses a recipe served through a Mitsubishi PLC touchscreen. Models are available offering maximum processing widths of 850, 1,100 and 1,350mm, with a minimum width of 300mm.

Roll sizes and weights can be up to 1,000mm and 1,000kg. Transfer roller sleeve changes are carried out quickly through the cantilevered mounting system. To achieve high levels of laminate adhesion, two corona treaters are supplied. An automatic fault diagnostic system allows customer support by either modem or the internet.


In-line innovations

Some novel coating and die cutting effects were demonstrated during a recent seminar on in-line coating on sheet-fed presses at KBA Radebeul’s new test printing plant.

On a Rapida 105 six colour with static eliminator and two coaters, a self adhesive film on a backing was printed in four colours with hybrid inks then given a matt UV coating using an offset plate in the sixth printing unit. With this method it is said to be possible to achieve a gloss level of around 5. The first coater was then actuated to apply a gloss UV coating.

KBA says seminar participants were “visibly impressed” by the matt/gloss contrasts achieved in offset register: a gloss level of 5 or so in the matt areas and 85 plus in the gloss areas.

After stopping the press briefly, the second coater was actuated and the printed and coated film was die cut in-line into individual shapes the size of a postage stamp, with serrated edges. The challenge lies in die cutting the film without damaging the backing, since it demands micrometer-fine accuracy similar to kiss printing on corrugated. This is only possible if the pressure of the die on the impression cylinder can be set with absolute precision, says KBA.


Nordson expands coating lab capabilities

The new CTL 4640 coater from Nordson allows the company’s global laboratory capabilities to help customers test non wovens and web coating applications, hotmelt adhesives and substrates in a controlled environment. The coater is available for demonstration and development trials at Nordson facilities in Dawsonville, USA, and Lüneburg, Germany.

The CTL 4640 provides coating and laminating on a variety of substrates or their combinations, including non wovens, films, foams, fabrics, tapes, labels and elastics. Operating at line speeds up to 600m/min with a maximum coating width of 350mm, it features modular back plates and rollers that reposition to accommodate different substrates and web path routing requirements.

A graphical user interface replicates production conditions, and an advanced tension control system provides ramp-up and ramp-down throughout the full line speed range without affecting substrates. The coater accepts numerous contact and non contact Nordson hot melt adhesive dispensing technologies.

The machine at the laboratory in Germany has additional capabilities that include a non contact curtain coat slot applicator and various contact slot applicators. It is also equipped with a QuadCure system for UV curable hotmelt adhesives.


Polytype customer goes multi layer

Polytype Converting reports success with several multi layer curtain coating projects for European and Asian customers. In 2005, the company received four orders for curtain coating equipment, all designed for simultaneous multi layer applications.

The first unit, with a width of 1,200mm and a production speed of 500m/min is for an Asian customer who produces three-layer thermal paper. The second unit has a 900mm, width and a maximum coating speed of 300m/min. It is for a pilot line at another Asian company that produces two-layer optical films.

The third coater, at 2,000mm and 600m/min, is destined for a European customer who produces three-layer inkjet paper. The fourth unit - 1,850mm and 750m/min - is for yet another customer from the Asian market who produces three-layer thermal paper.

For the past five years, Polytype says it has spent nearly 50 per cent of all trial times on its two pilot machines for single and simultaneous multi layer curtain coating applications. These include PSA adhesives for paper and film based labelstock, fluids with various barrier properties for paper and board based packaging products, aqueous lacquers for decorative papers, solvent based primer and adhesive fluids for packaging products with aluminum substrates, and highly viscous adhesives based on organic solvents for tapes.


Multi value metallizing

The Leybold Optics Pro-M coating system for packaging films is said to offer a combination of all options, substrates and processes on a single “multi value” platform. It can be used to metallize heat sensitive films, papers or even hot stamping film. Based on a variable component structure, the system can be adapted to customers ‘ individual needs. When requirements change, it can be upgraded accordingly.

The “highly efficient and fast” pumping system is complemented by high speed winding equipment capable of up to 14m/s. This features a quick response digital drive with synchronized AC motors and remote controlled “wrinkle-free” winding with four spreader rollers. Maximum coating width is 2,500mm, and all operations are monitored by a PC based control system.

Among the processes available is the company’s new FlexoPrintTechnology, which uses a small amount of oil to obtain free areas in metallization. This method usually produces view windows, but any conceivable pattern is said to be possible.

Metallized film replaces foil in pouch laminate

Unilever Foods North American Savory Division, has replaced the foil traditionally used in Knorr and Lipton paper/PE/foil/PE pouches with barrier metallized Torayfan PC1 BOPP film. It is said to have provided greater barrier stability and significant production savings.

Michael Hughes, group manager, packaging technology, says: “In a six month trial, the pouches made with the metallized film out-performed regular paper/PE/foil/PE packaging in delivering a better food product because of their superior moisture and oxygen barrier.”

The change achieved a number of performance improvements. “Better puncture resistance was very important to us because many of the products contain freeze dried noodles, which have very sharp edges. “According to the feedback from retailers, the problem of punctured pouches has been practically eliminated. Some of the punctures that used to occur with foil were so tiny that even the fine powders in the pouch were unable to get out, but air and moisture were able to get in. This does not occur with the new film.”

Improved consumer appeal was another benefit. “The problem with foil is that creases or wrinkles that occur during handling are permanent,” he says. “The pouches are handled when they are packed into cartons, then when they are taken out and put on the shelf, and finally by consumers. With all this, they can quickly appear shopworn. With plastics film, however, creases and wrinkles are temporary, and graphics stay sharp and clear.”

Converter American Packaging, of Rochester, NY, uses a tandem lamination process, with two extruders positioned in line. “The first step is extrusion lamination and the second is extrusion coating,” says technical director Larry Webb. Although this requires higher precision than foil lamination, it does offer several advantages. “For one thing, because it is only 50 gauge in thickness, it delivers more square feet per pound. For another, because of Toray’s proprietary ultra high surface energy and advanced metallizing technology, we don’t have to worry about the metal delaminating from the OPP film during high temperature extrusion.”


Economical option

Since its launch at drupa in 2004, the VCM Versatile Converting Machine is said to have been ordered by a number of leading manufacturers for use either as a pilot machine or for the small scale production of specialist products.

Developed by sample preparation system and coating technology specialist RK Print Coat Instruments, the VCM is purpose built to suit the requirements of each customer.

RK’s Tom Kerchiss says the economic disadvantages of using a production machine for pilot runs are so great that most manufacturers see the advantages of using a system such as the VCM for developing new coated products, testing substrate receptivity and quality control purposes.

It is also said to be ideal for use by companies that need a machine to produce low volume specialist products.

The VCM allows the user to choose from more than 15 different coating and printhead technologies including, hotmelt, meter bar, gravure (printing and coating), flexo, knife-over-roll, extrusion, reverse roll, gravure-offset (printing and coating) and slot die. It can also be provided with a range of drying/curing options, including hot air, IR and UV.



Contacts

KBA
Tel: +49 351 833 2580
Leybold Optics
Tel: +49 6023 500 0
Nordson
Tel: +49 4131 894 136
Polytype Converting
Tel: +41 26 426 1211
RK Print Coat
Tel: +44 (0) 1763 852187
Soma Engineering
Tel: +420 465 350 811
Toray Plastics (America)
Tel: +1 401 294 4511





External weblinks
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KBA
Toray Plastics (America)
Soma Engineering
RK Print Coat
Polytype Converting
Nordson
Leybold Optics

Polytype curtain coater Polytype curtain coater
Soma's solvent-free system Soma's solvent-free system


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