A company and its products are as strong as the people behind them. This is what we stand for with our conviction and, if necessary, with extraordinary ideas. As a producer, adhesive tape developer, problem solver and service provider, we are guided by this maxim. The most important goal for us is to find efficient solutions for the most diverse requirements of the industry. That's why we work intensively on product development - together with our customers. For an optimal solution.
Based on our coating systems and decades of experience, we offer interested customers a wide range of options for implementing customized solutions. It doesn't matter whether you want to apply a standard coating to a new film or have a new coating compound applied to a film provided.
Our services in adhesive tape development
If necessary, you will receive support from our laboratory in formulating the coating compound (our options are not limited to an "adhesive" application). We are also happy to assist you with the selection of raw materials (carrier materials) if required. Any necessary "aids" such as silicone paper, cover films or laminate partners are available in a wide variety. The minimum coating quantity should not be less than 1000m². The total capacity is several million square meters per year. Of course, the laminated goods can also be cut or formatted afterwards.
Project process for customized coating / contract equipment
New developments are always an attempt to find new, more economical solutions by taking a path that has not been taken before. In order to be able to quickly take advantage of such new developments, interested parties receive comprehensive support from us. To ensure that this customer-specific development runs as smoothly as possible, we at CMC Klebetechnik have divided this process into individual stages. This helps to avoid undesirable developments. In addition, the cost framework always remains comprehensible for everyone involved.
Preliminary discussion,
A new development (or contract equipment, contract coating) always begins with a technical/commercial discussion. The first step is to clarify what is at stake, whether our technical capabilities are suitable for the required end product and whether the expected price structure corresponds to that of the customer.
1. development
Regardless of whether you already have a ready-made recipe, provide us with the coating compound or whether we develop a completely new combination of carrier and coating together: We choose the right coating method to meet your specific requirements!
The fact that CMC Klebetechnik has its own development department is a major competitive advantage. Our chemical engineers are experienced developers for solvent and dispersion coatings. They can adjust the formulation of the coating in the laboratory so that it meets your requirements as precisely as possible. The laboratory is equipped with a large number of different measuring devices for this purpose. For example, a climatic chamber with UV lamps enables the simulation of outdoor exposure, combustion chambers to test flammability and SAFT testers to determine the shear strength of the adhesive under temperature stress.
Once the formulation has been determined, laboratory samples are produced. Various options are available for applying layers ranging from a few micrometers to around two millimeters. These samples can be used, for example, to check the even distribution of the coating mass or to measure the anchoring of the coating on the base film. This allows basic experience to be gained with the carrier (film, fabric, etc.) and coating compound. At this stage of development, different variants can be tested with little effort in order to provide you with samples of the best possible design. These material samples can be modified very quickly by making changes to the formulation. If the values determined are suitable, the next development step is the laboratory coating system.
2. coating
As soon as the recipe has been determined, tests can be carried out on the pilot coater. This coating system allows coatings to be applied very close to the conditions in the series production systems. In this way, tests with changing settings can be carried out quickly. The future parameters for the main coating systems are also determined in this step. Minor changes to the formulation can still be made easily and cost-effectively, allowing fine-tuning of the formulation for subsequent series production. This also makes it possible to produce small pilot series samples with which you, the customer, can carry out initial tests. Not much material is required for these initial tests. Samples can be produced on the laboratory coater with just 10 m of material, at a cost of EUR 500 per hour or part thereof plus material costs. These costs can be offset against a later series production. You will receive the product in the shape you require.
Preliminary tests on the laboratory coater minimize the need for much more complex changes when scaling up to the production plant. Formulation and prototyping as well as laboratory coating can be carried out very quickly if required. This has enabled customers to outsource parts of their development to CMC Klebetechnik.
3. test coating on the line
If the tests on the laboratory coating system are successful, the next step is to carry out near-series production tests on the main coating systems. The first step is to check whether the parameters from the preliminary tests can be adopted directly. During the test coating, all relevant parameters are recorded, which then form the basis for the final price calculation (e.g. coating speed). You are welcome to be present during these tests.
Costs: 1.000,- EUR/per hour or part thereof plus material and, if applicable, assembly costs.
In both systems, the material to be coated is pre-treated using corona technology. This improves the wetting and anchoring of the coating material on the substrate. An automated web tension control system keeps the transport forces at a constant level over a wide range. This means that substrates between a few micrometers and a few millimeters thick can be coated. A laminating station on both coating systems enables the coated material to be laminated inline with an additional film or fabric or a siliconized cover.
During production, the quality of the goods produced is monitored by computer. Standardized tests or tests agreed with the customer are carried out and documented in the laboratory on every jumbo roll produced.
After three test coatings have been carried out with unchanged parameters, series production usually begins.
Laboratory coating system
Technical data
- 3-zone hot air dryer up to max. 155°C
- Dryer length 5 m, speed between 0.5.....5 m/min
- Maximum web width 300 mm, usable width usually around 260....270 mm
- Laminating station for laminations
- Possibility of adding a cover (PE film, silicone paper, etc.)
- Usual lengths for sample production 10....50 running meters
Measurement options in the development laboratory
Effective development work also has to do with good laboratory equipment. In addition to a modern and generously equipped laboratory, we have a wide range of facilities for carrying out measurements and tests. Here is a brief selection:
- Pilot coating system for the manufacture of production-related samples with a maximum width of 270 mm and a maximum length of approx. 100 m
- Climate chamber, Weiss, humidity up to 100 rel %, temperature -70 ...+180°C
- Several heating ovens up to 350°C for rapid ageing tests, for example
- Vertical combustion chamber for flammability tests in accordance with UL94-V and IEC 60454
- Horizontal combustion chamber for flammability tests in accordance with UL94-H and IEC 60454
- Measuring device for determining the electrical resistance (electrical conductivity)
- High-voltage tester for determining the breakdown voltage up to 15kV AC
- Various viscometers for determining the viscosity of adhesive solutions
- Several precision scales
- Measuring device for determining the residual solvent content (volatile solvent measuring device)
- Thickness sensor: scale graduation +-1µm
- Micrometer: scale graduation +-1µm
- Portal tensile tester from Zwick; load cell upper limit 500N, +/- 0.5% of the measured value, for determining adhesive forces, tensile strength and elongation strength
- PH electrode: PH 0 to 14 for measuring the alkaline or acidic properties of solutions
- Precision ruler with measuring magnifier (0.01 mm graduation), for example for measuring the shrinkage of films
- Microscope with digital camera attachment for surface examinations
- Equipment for determining shear strength even at elevated temperatures (juice test)
- Kofler bench for determining the melting temperature of adhesives and polymers
Film coatings - from trial to market
How often do you have a good idea but not the opportunity to try it out or implement it? Manufacturers who are developing a coated product and don't yet know how big the chances are for it on the market also experience this. It's nice when you can simply start a trial with relatively little effort.
The list of sample coatings, customer-specific coatings and contract coatings carried out at CMC Klebetechnik is now very long.
The opportunity to carry out initial trials on a special pilot coater (laboratory coating system) on a much smaller scale close to production is particularly popular.
Dies reicht von witterungsbeständigen Folienbeschichtungen als Reflexionsoberfläche bis zu nanostrukturierten Leitlacken, die als elektrische Heizung eingesetzt werden, von Gewebeimprägnierungen für Verbundmaterialien bis zu Kleberbeschichtungen von medizinischen Faserstoffen, von Isolationen für Hochtemperatur-Supraleiter bis Dekorfolien für Möbeloberflächen, von Anwendungen im Brennstoffzellen-Stack bis zu kohlefaserverstärkten Klebebändern als Ersatz für Stahlseile.
The advantage of the laboratory coater is the short set-up time, the very fast and direct access to the test set-up and the possibility of producing 100m lengths of web. Customers who process web-shaped materials themselves and whose machines are five or ten meters long often require sample material that has a certain minimum length.
Two or three hours of sample coating on the pilot coater are usually enough to obtain the first representative samples for a product presentation.
CMC Klebetechnik also offers the option of producing small quantities on a trial basis on the main coating systems. Film, fabric, nonwovens or paper can be produced cost-effectively from just a few 100m². The system can be rented to the customer on an hourly basis. Of course, CMC Klebetechnik's concentrated production and application knowledge is available to the customer.
Variants of such contract coating include the provision of the carrier film, the coating compound or all components. Such initial trials naturally also serve to determine the optimum process parameters in addition to a saleable product. Even if the product is to be coated by a different coater at a later date, decisive parameters can be analyzed at this early stage of product development (e.g. coating speed).
CMC Klebetechnik is therefore not only a manufacturer of technical adhesive tapes, but also a development partner for customer-specific solutions with its own development department.