Custom coatings - Toll coatings - taylor-cut

custom coatings

CMC coating technology is a strong and competent partner for the design and implementation of customer-specific solutions. We understand your requirements and translate these professionally realise to products and processes. For you this means professional coating solutions from a single source.

Although there are many combinations of film, fabric or paper with (adhesive) coatings on the market, an individual solution can decisively contribute to whether a product is successful on the market or can be manufactured at all. The optimal matching of a product to the technology required for its further processing reduces costs and therefore constitutes an important competitive advantage for your company.
Because in a market with comparable products, in Europe gaining an advantage over the competition only in terms of price is successful less and less often.
The potential uses for solvent and dispersion adhesives and the flexible, low-setup-cost coating systems open up many more possibilities than with a specialised coater, as these can produce optimally but usually only two or three products.

Reasons for out-sourcing

  • No in-house development capacity
  • Overcoming bottlenecks
  • Focus of competence lies somewhere else
  • No competitive situation (other customers, other markets, other technologies)
  • System technology not available or unsuitable
  • Concentration on one's own core competence


With our different coating facilities and our decades of experience we offer interested customers wide-ranging possibilities for the realisation of customer-specific solutions. And it is immaterial whether you produce a new film with a standard coating or apply a new coating compound to a film provided. Our Development Department will support you with the formulation of the coating compound (our possibilities are not limited to a simple "adhesive" order).

In order to obtain optimal conditions for the first test coating, the first development steps can be investigated on a pilot system before commencing serial production.
The consequent further development of the production technology and the technical periphery makes it possible today to coat nearly any film-type material on the coating facilities. So it doesn't always have to be an adhesive which is applied.

CUSTOM AND TOLL COATING CAPABILITIES
 Line 10Line 20Pilot Coater
Machine Width1550 mm (61 inch)1900 mm (74,5 inch)300 mm (12,5 inch)
Web Width500 mm (19 inch) to 1500 mm
 (59 inch)
500 mm (19 inch) to 1890 mm
 (74 inch)
Aprox. 250 mm (10 inch)
Web Thickness6µ (0,23 mil) - 250µ (10mil); up to 1000µm (39 mil) on spez. request6µ (0,23 mil) - 250µ (10mil); up to 1000µm (39 mil) on spez. Request12µ (0.5mil) - 250µ (8mil) 
Mechanical Speed1 to 50 M/min1 to 35 M/min0.5 to 5 M/min
Maximum Web OD
and Weight
UW: 750mm (30 inch), 850 kgUW: 1000mm (40 inch), 850 kgUW #1 and #2: 250mm (10 inch)
W: 300mm (12 inch)
Core IDUW: 3 or 6 inch
W: 3 or 6 inch
UW: 3 or 6 inch
W: 3 or 6 inch
UW: 3 inch
W: 3 inch
Coating Layers Per Pass1 Coating Stations
1 layer per run
2 Coating Stations
1 layer per run
1 Coating Station
Multi Coating Mehtods
ROD, KNIFE, GRAVURE, REVERSE
Liquid TypesSolvent BasedSolvent Based
Aqueous
Solvent Based
Aqueous
Drying CapabilityMax Dryer Temp: 300°F (150°C)Max Dryer Temp: 300°F (150°C)DRYER
Jet Nozzle Hot Air Circulation
Min. 60°C ~ 150°C
Other CapabilitiesOnline Thickness Monitoring
Corona Treating
Inline Camera Inspection
Inline Slitting
Paper Insertion
Laminator with Heated Roll
Online Thickness Monitoring
Corona Treating
Inline Slitting
Paper Insertion
Laminator with Heated Roll
Laminator with Paper/Film Insertion
Off-line Slitter, Rewindling, Sheeting
Further capabilitiesDevelopment Laboratory, Support for Customers, Extensive Mixing Capabilities"Quick and dirty" first
test-coatings for fast results

 

 

In the film and adhesive tape industry very large quantities are frequently produced. One reason for this is the often very high investment costs for the production facilities. In this case, only mass production can cover the initial costs and the running costs.

However, companies specialised in the cost-effective production of large quantities mostly set store by only one or two products. And these then have to run day and night, if possible seven days a week.

With CMC coating technology this is different. The coating facilities are far slower than high-output coaters, which apply up to 1000m per minute. Yet, if we examine the requirement for Teflon® film, for example, it becomes clear that such a high-output coater is unsuited for this material:High-output coaters coat very fast on systems which are as long as possible. This can mean that while setting up the machine a large quantity of material is already applied with incorrect settings. Furthermore, thousands of square metres are very quickly coated.

But the requirement for such expensive films as Teflon® is not of the order of magnitude of "thousands of square metres". So, after a short time another product must be produced. Specialised facilities are not designed for this. The setup times can be very long and therefore drive up costs.

CMC coating technology coats exactly in the areas which large coaters cannot cover. Production batches of around 500m² to several thousand square metres are usual. In the cross-fire between coating speed and setup effort, this achieves optimal balance and therefore optimal pricing.

CMC coating technology has two systems for solvent-based coating compounds, one of these up to 1,900mm wide. Between approximately 10µm and 1000µm coating material can be applied, while normally up to around 150µm dry is sufficient.

Thus, it is no surprise that since 2009 more and more companies are seeking outsourced coating. Competitors are also shifting small production volumes of a few thousand square metres from their large facility to the more flexible and more cost-effective coating facilities of CMC coating technology.

By contrast with coaters specialised in only a few products, CMC coating technology has very extensive experience with different materials and applications. The many interested companies benefit from this knowledge.
Whether for special constructions in battery or fuel cell technology, medicine, constructions in the aviation industry or in safety engineering: All applications have their specific requirements which must be translated to the right blank films and coatings.

Class and not mass is therefore not meant in the sense that mass is bad. Far more, it describes the field of activity of CMC coating technology. Solving problems with small and middle-sized requirements and special requirements for the performance and individuality of the product.

Toll Coating / Contract Manufacturing

Your "own" product in three steps

You want to have a product fitting exactly to the application you have?
You can not find a standard product on the market?

Ask us for a solution!

Custom coatings can cause siginificant cost reduction because the coating can be designed exactly fitting to your application and no need of changing your further processing. Custom coatings can be a exclusive feature making the decisive difference.

Step1

  • First Contact
  • Definition of the demanded properties
  • Samples made in the laboratory
  • Verification of the samples


Step2

  • First sample-coating on the pilot-coater or a large-scale coating machine
  • Verification of the production
  • (depending on kind of coating and quantity with cost-sharing)


Step3

  • Mass production
  • If necessary with cutting and formatting
  • Permanent improvement and optimization
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