1. In-Line Coating Application
In-Line Coating Application
Presented by: Thies Janczek
COCASO - Thies Janczek - President

2. In-Line Coating Application
Content
Introduction
Technology
Advantages
Economical
Technological
Current Applications
Summary
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

3. Introduction Laminated card
In-Line Coating Application
Introduction Laminated card
Overlay
Print
Print
on Mono-Core
Print Material (PVC) in thicknesses of to 760 µm in a special grade of white. split core with 2 printing sheets or mono core – 1 sheet printed both sides
Core
Core
Print
Overlay
Printing multi color litho, UV curing
Overlay - special adhesive coating.
Core only in 6-layer constructions
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

4. Introduction Laminated card
In-Line Coating Application
Introduction Laminated card
Print
Overlay
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!
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

5. Technology Flexo Coater on litho press
In-Line Coating Application
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)
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

6. Technology Flexo Coater on litho press
In-Line Coating Application
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
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

7. Technology Water based on a litho press
In-Line Coating Application
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.
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

8. Technology Dry versus Wet adhesive
In-Line Coating Application
Technology Dry versus Wet adhesive
Printsheet
Overlay
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
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

9. Technology Adhesion after Lamination
In-Line Coating Application
Technology Adhesion after Lamination
Overlay
Printsheet
Effect exaggerated
Bond to inconsistent print sheet surface
Need for good flow properties cause distortion effects
Hot melt  melt-temp does not change
Bond to consistent overlay surface
Only low flow properties are needed
Heat started x-linking raise melt-temp  permanent bond
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

10. Advantages - Ecological
In-Line Coating Application
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
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

11. Advantages - Ecological
In-Line Coating Application
Advantages - Ecological
Example calculation per laminate:
Conditions (most probable)
50µm standard PVC Overlay
5µm coating thickness
48 cards per sheet (size 620x520mm)
SAVE more than 17 cent per laminate
Calculation considerations:
For a repeat of 2 x 3x8 a sheet size of 620 x 520mm is considered
Weight for a 50µm OV sheet with a density of 1,33 g/cm³ is 21,44 gramm
Weight for OV like above with 5 g/m² adhesive coating is 23,05 gramm
Cost estimated for
uncoated OV 3,00 €/kg
Coated OV 6,60 €/kg
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

12. Advantages - Calculate your numbers
In-Line Coating Application
Advantages - Calculate your numbers
Enter your numbers into the table to do your calcultions.
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

13. Advantages - Technological
In-Line Coating Application
Advantages - Technological
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
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

14. Advantages - Technological
In-Line Coating Application
Advantages - Technological
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
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

15. In-Line Coating Application
Current Application
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
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

16. Scenario ROI on a stand alone coater
In-Line Coating Application
Scenario ROI on a stand alone coater
Simple calculation for an overview:
Estimated invest: €
Saving per card: 0,36 €cent
Annual production: 200 Mio cards
ROI is under 2 years (22 months)
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

17. In-Line Coating Application
Summary
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
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

18. In-Line Coating Application
In-Line Coating Application
ANY QUESTIONS ?
CONTACT US !
COCASO – Thies Janczek – Moewenstrasse 5a – Molfsee – Germany
Phone: +49-(0) – OR
FUNCTIONAL MATERIALS INC. – Josef Feldman – 150 Route 17 - Sloatsburg, NY
USA – Phone: –
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President

19. In-Line Coating Application
17/09/2018
Customer Presentation
COCASO - Thies Janczek - President