The biggest problem facing the coating and laminating converter today is the manufacture of high quality, high performance laminations in the face of today's environmental constraints. The converter is confronted in one case with increasingly demanding structures while at the same time facing restrictions of solvent emissions, OSHA, and waste disposal legislation.
There are numerous advantages for the converter that have come from the development of the 100% solids coatings and laminations, such as the environmental benefits of no solvent emissions, reduced worker exposure to solvents, and reduced hazardous waste disposal. In addition, without dryers and incinerators, there are economic advantages such as reduced energy costs, lower capital equipment costs, reduced space requirements, and lower installation costs.
With continuous downsizing of materials, thinner gauge materials can be run due to the shorter machine web path, elimination of heat from dryers, and improved web tension control. In addition, since the 100% solids process requires a thinner adhesive thickness and no solvents, there is a savings here as well.
Two other important advantages that must be considered are fast changeover in less than 30 minutes for shorter runs and higher speeds for longer runs. In fact, without dryers, the solventless process likes higher speeds, up to 1,500 fpm currently.
The future looks bright, especially when one considers the development of a new generation of barrier adhesives. The quality of the final structure is enhanced by better bond strengths and improved clarity. Without the problem of retained solvents, the final performance features have been greatly improved.
Multipurpose coater-laminators, with trolley units can handle not only all current adhesives but can be made to handle UV adhesives and coatings, including UV pressure-sensitive and silicones. Electron beam costs are comming down, making this process more economical for expanded markets. Additionally, hot melt adhesives and coatings can be run on a modified version. Inline solventless machines with flexo and gravure presses are possible with servo drives and register controls making registered pattern coating possible.
