1. Let’s Make Tape (Coating Technology)
Pressure Sensitive Adhesive Tapes for Sales and Marketing Professionals
Tape University Basics May 12, 2009
Let’s Make Tape (Coating Technology)

2. Tape Making Process QC
Materials
Coat
Convert/Package
Inspect

3. Generic Coating Line Increasing Value Additional Components Rolls
Unwind
Applicator
Cooler/Dryer
Winder
Slitter
Additional Components
Web Surface Treatment
Thickness Gauge
Solvent Treatment
Tension Control
Edge Guide
Laminator
Rolls
Master Roll
Cooling Rolls/Oven
Liquid/100% Solids
Inspection May Occur at Various Process Points
Substrate/Liner
Materials
Increasing Value

4. Common Coaters Knife Over Roll Calender Gravure
Liquid Adhesives
Requires Drying Oven
100 Percent Solid Adhesives
Knife Over Roll
Gravure
Reverse Roll
Mayer Rod
Slot Die
Calender
Extrusion Coater, Slot Die
Coater selection is determined by type of adhesive, thickness, and thickness tolerance which impact cost.

5. Calender Characteristics Speed: 200m/min max
Thickness: 100-2,000 microns
Viscosity: 50-50,000 Pa.s
Examples: Duct Tape, Pipewrap Tape, Building and Construction Tapes

6. Liquid Adhesive Coater
Commonly used to coat solution and emulsion based adhesives onto a variety of webs.

7. Characteristics of Coater
Coating Head
Viscosity, Pa.s
Wet Thickness, microns
Max Speed, m/min
Mayer Rod
5-100
200
Gravure
0.01-5
2-50
700
Knife Over Roll
25-750
150
Reverse Roll
400
Coating head selection based upon adhesive thickness and coating line capabilities

8. Hot Melt Coater Speed: 700 m/min max Viscosity: 50-1,000 Pa.s
Thickness: microns
Examples: Carton Sealing Tape, HVAC Tapes, Mailing Envelope Tapes

9. Summary
Choice of coating method is a designer’s prerequisite for meeting cost, functionality, and uniformity.
There is both a science and an art to coating which refers to esoteric properties of fluid which are hard to model or predict.
Experience and specific knowledge will determine whether corrections are made to the machine or to the fluid and their limitations.