Gravure-Coating in Printing

Infeed and Out feed Coating
S.MEENAKSHI
2011113015
1
COATING
 A coating is a covering that is applied to the surface of the

substrate.
 The purpose of applying the coating may be decorative,
functional, or both.
 Example: adhesives and lacquer.
2
Coating Types
Water Based
Solvent Based
100% Solids (UV and E-Beam Cure)
Hot Melt: Adhesives and Waxes
3
EXAMPLES
High Gloss Coatings & Adhesives Coatings
High Abrasion Resistant Coatings
Work & Turn Coatings
Matte/Satin/Semi-gloss Coatings
Primers for UV and Film Lamination
Heat Resistant Coatings
Non Skid & Controlled COF Coatings
FDA Complaint Coatings
Pearlescent Coatings
Foil & Plastic Substrate Coatings
Special Substrate Coatings
Ink Train Coatings
Custom Developed Coatings
ADVANTAGES OF WATER BASED
COATINGS
 Provide gloss, abrasion resistance, controlled COF and many other
functional properties.
 Quick speed of drying.
 Fast press speeds and turn around times.
 Eco friendly
 VOC content is generally very low or negligible in quantity.
 Water base coated paper can be recycled very easily.
 Non yellowing and
 No residual odor.
Disadvantages of Water-Based Coatings
• 1. It may be physically washed off if rain falls onto a freshly painted

water-based coating
• 2. It is susceptible to frost damage when wet. Must be protected from
frost during transport and storage.
Advantages of Solvent-Based Coatings
• 1. They produce almost immediate waterproofing protection after

application, even before they have dried.
• 2. They are not damaged by freezing temperature.
• 3. They often give better surface penetration and hence better adhesion
to porous surfaces.
Disadvantages of Solvent-Based Coatings
• 1. Some solvent-based products can be harmful to health.

• 2. They give off solvent fumes and hence require good ventilation.
• 3. Most are flammable.
• 4. They can attack plastics and bitumen.
• 5. Applicators will require special protective clothing and special hand
cleaner to remove splashes.
• 6. Special solvents are needed to clean equipment after use.
• 7. Solvent-based products cannot be applied onto damp surfaces. They
are incompatible with such surfaces, which must be allowed to dry fully
(including all trapped moisture must be given time to rise and evaporate)
before application commences.
Classic Gravure Coater
 Sections:
 Coating Reservoir (Pan)
Coated Incoming
Web Web  Gravure Roll (Etched Metal)
 Doctor Blade
 Impression Roll (Rubber)
Impression /
Back-up Roll  Process:
 Coating Pick-up
Doctor ○ Fill Cells
Blade
 Wipe (Doctor) Excess
Gravure
Roll  Transfer Coating
○ “Empty” Cells (Transfer Efficiency)
○ Film Split
Coating Pan
9
Coating Pan
Doctor
Blade
 Function: Delivers Coating to Gravure Roll
Gravure
 Maintain Constant Level
Roll
 Stand Pipe or Overflow Weir
 Consistent Coating Movement

 Continuous Recirculation
Supply Return  Foam Management
 Avoid Solids Settling
Doctor
Blade  Enclosure / Covers
Gravure  Minimize Solvent Evaporation
Roll
 Contain Slinging
 Pneumatic Pan Lift
Return Return
Supply 10
Enclosed Applicator
 Enclosed System
 No Slinging of Coating
Coated Incoming
 Minimizes Solvent Evaporation Web Web
 Reduced System Volume
 High Rate of Recirculation

Impression /
 Minimizes Air Entrapment Back-up Roll
 Foam Control – Flows Out of

Chamber
 Easy to Clean Gravure
 Simple Flushing Systems Roll
 Minimize Waste
Return
Supply
11
Enclosed Applicator
12
INFEED COATING
 Some webs require prime, base or anchor coating to

help the inks adhere to the substrate.
 Coating is done on the first gravure unit.
 This unit can apply ink, coating or adhesive layer on
either side of unprinted web.
 Most gravure printers prefer to apply back side coating
after the printing has been completed because its
possible for the heat or cold seal adhesives to soften
during their travel through subsequent printing dryers.
OUTFEED COATING
• Application of decorative gloss, protective and anti-slip coating over

printing
• Inline application of package sealing adhesives on the unprinted
side of the web
• Heat-seal coatings are thin layers of a colorless liquid which form
permanent package sealing bonds when heated to a softening point
and squeezed against another uncoated material under moderate
amount of pressure
• Cold-seal or cohesive adhesives are dried layers of a colored liquid
which adheres to another solidified layer of cold seal coating.
COATING
 There are three types coating methods
1. Allover
2. Pattern
3. Striping
 Allover coatings are deposited over the entire area of
web
 Pattern coatings are applied in a specific design.
• Gloss coating will prevent good sealing and therefore
those areas to receive hot seal adhesives are left free
of coatings
• Strip coating is a form of pattern coating in which
adhesive design consists of several narrow
continuous ribbons which run in web direction
• This process is used to apply package sealing
adhesives
Variations
 Reverse Gravure
 Offset Gravure
 Differential Offset Gravure
 Two-Side Coating
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Reverse Gravure
 Reverse Application
 Speed Range: 90-120%
Coated Incoming
Web Web  Benefits
 Removes Cell Pattern
 Film Split Avoided
Impression / ○ Minimizes Ribbing
Back-up Roll
 Adjust Coat Weight with Roll Speed
 Impression Control is Critical
Doctor
Blade
 Light / Controlled Impression
 Precision Required – Better Rolls
Gravure
Roll  Driven Impression Roll
 Suggested for Tension Control
 Overcome Reverse Action
Coating Pan
23
Offset Gravure
Coated
Web
Incoming
Web
 3-Roll System
 Gravure is Offset from Substrate
Steel  Removes Substrate from Coating Nip
Back-up Roll
○ Protects Sensitive Substrates
Film
 Roll Rotation
Split
 All Roll Same Direction
Rubber
○ Synchronous Rotation
Applicator Roll
“Forward”
 Two Film Splits
 Thinner Coatings
Film
Doctor
Blade
Split  Roll Speeds
Gravure  All Rolls at 100% Line Speed
“Forward”
 Single Drive is Possible
○ Gravure Roll is Typically Driven – Idle Mode
○ Applicator Roll is Nip Driven
Coating Pan ○ Back-up Roll is Web Driven
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Differential Offset Gravure
Coated Incoming
Web Web  3-Roll System
 Roll Rotation
Steel
Back-up Roll  Gravure: Forward / Reverse
 Applicator: Forward / Reverse
Film
Split  Roll Speeds
 Gravure: Variable
Rubber
Applicator Roll
Fwd / Rev
 Applicator: Variable
 Back-Up: Controls Tension
Film
Doctor Split
 All Rolls are Driven
Blade
Gravure
 Roll Function
Fwd / Rev  Gravure: Coat Weight Control
 Applicator: Appearance Control
Coating Pan
25
Simultaneous Two-Side Coating
• Very Cost Effective

– Coat Both Sides at One Coating Station
– Single Dryer vs. Dual Dryers
– Reduced Overall Line Length
• Direct Application (Kiss Coating)
Gravure – Forward or Reverse Apply
Roll – Coat Weight is Susceptible to Tension
Variations
• Limited Range of Applications
Gravure – Thinner Coatings
Roll
– Same / Similar Functional Coatings on
Both Sides
Two-Side Coating
A2p
G2avu GG2ara
Roll vure
A2plic
Roll
A1licat
Gravure Roll
G1
Roll A1Ap
Gravure pli
G1
Roll
• Offset Coat  Offset “Kiss” Coat

– Supported  Unsupported
Versatility
 Top Coats for Wear Resistance on • Lamination Adhesives for Medical
Magazines Drapery
 Gloss / Color Snap Coatings for • Primer Coatings for Aluminum Layer
Automotive Brochures in Cigarette Packaging
 Adhesives for Wood Grain Patterned
• Optically Clear Adhesives for Bottle
Coverings on Furniture
Labels
 Gas Emissive Coatings for Medical
Packaging • Adhesives on Masking Films
 Protective Coatings on Appliance • Reactive Coatings on Thermal
Overlay Papers
 Optically Clear Adhesives for Protective • Pre-Paste on Wall Coverings
Window Films
• Tinting of Decorative Fabrics
 Silicone Based Release Liners for
Medical Bandages • Laminating Adhesives for Lottery
Tickets
 Pressure Sensitive Adhesives for
Medical Bandages • Bonding Layer for Foam / Fabric
Headliners
28
THANK YOU
29

Gravure-Coating in Printing

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Infeed and Out feed Coating

 A coating is a covering that is applied to the surface of the

• 1. It may be physically washed off if rain falls onto a freshly painted

• 1. They produce almost immediate waterproofing protection after

• 1. Some solvent-based products can be harmful to health.

 Consistent Coating Movement

 Pneumatic Pan Lift

 Reduced System Volume

 High Rate of Recirculation

 Foam Control – Flows Out of

 Some webs require prime, base or anchor coating to

• Application of decorative gloss, protective and anti-slip coating over

• Very Cost Effective

• Offset Coat  Offset “Kiss” Coat

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