Coating Technology for Flexible Packaging

Lee A. Ostness
Product Manager - Coating & Drying Systems

Flexible Packaging is widely used in today’s world. It is used to package

a multitude of products such as: processed meat, processed cheese,
fresh red meat, bulk liquids, cereals, cake mix, coffee, medical device
films, snacks and many others. There are many different substrates and
coatings used to create these packages to produce the various levels of
barrier protection. see chart

SUBSTRATES COATINGS
PET 1 – 10 mil Primers 0.04 – 0.4 gsm
PE 1 – 8 mil Adhesives 3.25 – 6.5 gsm
Al Foil 20 – 60 µ PVDC 1.6 – 6.5 gsm
BOPP/OPP 0.4 – 2 mil Wash-coats 0.8 – 1.5 gsm
CPP 1 – 4 mil PVOH 0.5 gsm
Nylon 0.4 – 2 mil Lacquers 5.0 gsm
MetPET 1 – 10 mil Varnishes 0.02 – 0.04 gsm
Cellophane 0.8 – 1 mil Acrylic Polyurethanes 0.3 gsm

A typical package may be constructed of several layers of substrates and

coatings. Two typical constructions are illustrated below. The beverage
package is constructed with PET/Printed/Primer coating/LDPE/Foil/LDPE(heatseal).
The Retort Package is a different construction requiring two coatings,
PET/Printed/Adhesive coating/Foil/Primer coating/LDPE. The foil is a barrier
layer and may be substituted with Metalized PET, Nylon, or EVOH
depending on the amount or type of barrier required. see illustration

PET 12.6µ PET 12.6µ

(PRINT) (PRINT)
PRIMER 0.04µ ADHESIVE 3.25 – 6.5µ
LDPE 12.6µ FOIL 6.3µ
FOIL 6.3µ PRIMER 0.04µ
LDPE (Heat Seal) 25µ LDPE 25 µ

Beverage Package Retort Package

The constructions incorporate the use of solution coating(s) to enhance
either the barrier and/or the adhesion properties. The focus of this paper
is to discuss how these coatings are applied.

A solution coating is a liquid with solids dispersed in the liquid to assist

the wetting of the substrate it is applied to. The
liquid can be a combination of solvents or water
determined by its ability to maintain the dispersion
of the solids. The solution coating is applied to a
continuous web with a Coater and then passed
through a Dryer to remove the liquid leaving a thin
layer of solids on the substrate. The coater will be
either a gravure type or a smooth roll type. The
dryers are normally a roll support design or a
floatation design. The roll support dryer consist of
rolls supporting the web with opposing impingement nozzles drying the
web. The floatation dryer consist of nozzles on both sides of the web
creating a sign wave affect to float the web.

Coating heads have a variety of applications, strengths and weaknesses.

How do you objectively select the right coating head? There are 50 plus
coater configurations available to apply an infinite number of coating
solutions. To select the coater for your needs you first need to know
your coating and substrate’s properties, then match these properties with
the coater’s abilities/limitations.

Coating Substrate Coater

% Solids Absorbency Speed Range
Viscosity Surface Tension Coat Weight Range
pH Tear Strength Solids Range
Shear Stability Smoothness Viscosity Range
Density Caliper Appearance
Solvent/Water Based Melt Point
There are four main coater configurations used in the Flex Package
construction. The four types are Direct Gravure, Reverse Gravure, Offset
Gravure and Smooth Roll. The
gravure coaters utilize steel rolls
with patterns engraved into the
face of the roll. This pattern
determines how much coating is Direct
Gravure
Reverse
Gravure
Offset
Gravure
Smooth
Roll

carried to the web. The coating is

applied to the gravure, metered off the surface, leaving coating only in
the engraved pattern, then transferred to the web that is supported by
the rubber covered back-up roll. The smooth roll coater applies the
coating from an open pan, picking up the coating with a smooth steel roll
partially immersed into the pan, then the web is pressed against the steel
roll with the rubber covered back-up roll. The speed of the steel roll and
amount of pressure against the steel roll combine to control the amount
of coating applied to the web.

The gravure roll is a steel roll with a precise pattern engraved into the
surface of the roll. There are several gravure vendors, each with their
own names for these patterns. The picture shows one vendor’s patterns
and the names associated
with them. The patterns
are called from left to
right; Tri-Helical, Pyramid, Quadrangular, and Hexagonal. The amount
of coating in each cell (pattern) is measured and referred to as Billion
Cubic Microns (BCM). To select the correct gravure pattern for your
application, you need to reference a coat weight chart provided by most
gravure vendors. On this chart locate your coat weight under the percent
solids column that matches your formulation. Then follow the row to the
left and it determines the volume required to deliver the desired coating
to the substrate.
This chart is setup for the Direct Gravure method. The Reverse Gravure
method will need to add approximately 20% to the desired coat weight
and for Offset Gravure method add approximately 75%. This will be
explained as we discuss each type of coater and their operating
parameters.

The chart is only a starting point to get you close to your target. A large
amount of the time the gravure pattern will need to be adjusted to
achieve the correct coat weight due to the different coating and/or
substrate characteristics.

Direct Gravure Coater:

The Direct Gravure Coater consists of a rubber
covered back-up roll, a gravure roll, and a coating
applicator. The back-up roll is covered with a rubber
compound and is used to transport the web through
the coating process. The back-up roll is pressed
against the gravure roll creating a slight nip which pulls the coating out
of the gravure cells and deposits the coating onto the web. The gravure
roll is a steel roll with a pattern engraved into the face of the roll. These
cells are filled with the coating and doctored of the surface of the roll
 leaving a precise amount of coating on the gravure roll. The roll then
transports the coating to the nip where it is transferred to the web. The
coating applicator is either an enclosed chamber with two doctor blades
or an open pan with a doctor blade assembly to remove the excess
coating. In the Direct Gravure mode the gravure roll and
the web are moving in the same direction at the point of
GSM

contact. The speed of the gravure roll is usually the same

as the web but it may be adjusted to ∓10% of the web
95% 100% 105%
speed. The coat weight is determined by the gravure
Gravure Speed volume and the coating solids.

Reverse Gravure Coater:

The Reverse Gravure Coater consists of the same
equipment as the Direct Gravure coater. In this
method the gravure roll runs in the opposite
direction to the web and varies in speed from 50%
to 150% of web speed. The most common
operating speed is 110% to 120%. The coat weight
in this mode when plotted will create a bell shaped curved by running the
gravure roll from 50 to 150% of web speed measuring the coat weight
every 10%. If the same gravure pattern from the Direct gravure is used
the highest coat weight will only be about 80% of the direct
gravure methods. The coat weight is determined by the
GSM

gravure pattern, the coating solids, and by the speed of the

gravure roll. This method will lay the coating down with a
smoother appearance because of the shearing action
Gravure Speed created at the nip. The appearance created by the direct
50% 100% 150%

gravure method is a rougher texture because at matched speeds and in

the same direction you are virtually printing the pattern onto the web.
Offset Gravure Coater:
The Offset Gravure Coater consist of a steel back-up
roll, a rubber covered applicator roll, a gravure roll,
and a coating applicator. The back-up roll is chrome
plated steel roll used to transport the web through
the coating process and create the nip between the
web and the applicator roll. The Applicator roll is a
rubber covered roll used to transfer the coating from
the gravure roll to applicator roll, to the web. The gravure roll is a steel
roll with a pattern engraved into its surface. The coating applicator is
either an enclosed chamber with two doctor blades to an open pan with a
doctor blade assembly to remove the excess coating. In this method all
the rolls are turning in the same direction at the point of contact at each
nip. The back-up roll is operating at line speed, the applicator roll most
usually is operating at 98% of line speed (∓5%), and the gravure roll
operates at 25 to 35% of line speed. With this method
the coat weight curve when plotted would be a steady
GSM

incline then level off to a fairly straight plain. The curve

would be generated by varying the speed of the gravure
roll from 5% to 100 % in increments of 5%. The coat
10% 60% 100%
Gravure Speed weight usually levels off when the gravure roll reaches
about the 60% of line speed. The shearing action created by the
differential speeds and the two nip points generally apply a smooth
coating.

Smooth Roll Coater:

The Smooth Roll Coater consist of a rubber covered back-
up roll, a steel chrome plated pick-up roll, sling guards
and a coating pan. The back-up roll is covered with a
rubber compound and is used to transport the web
through the coating process. The back-up roll is pressed
against the pick-up roll creating a slight nip. The pick-up roll is
immersed into the coating pan and transports the coating to the nip
between the web and the pick-up roll. The coating is applied to the web
 at this nip point. The amount of coating applied is dependent on the
hydraulic forces at the coater nip created by the speed of the pick-up roll
and the nip force. The coating pan is filled with a solution coating and in
most cases it has an overflow weir so the coating may be recirculated.
The rubber compound selected has to consider several operational
conditions. The parameters consist of the durometer, surface tension,
resilience, tear resistance. The durometer needs to be based on the
speed of the machine line and the viscosity of the coating. With this
method the coat weight increases with higher speed and higher viscosity.
The surface tension is selected based on the compound of the rubber.
This method requires the rubber to repel the coating, so only the web will
be coated. The resilience and tear strength are required due to the high
forces and different web widths. The coat weight is determined by the nip
¼” width and the pick-up roll speed and the curve will be a line
½” with a slow incline and then when the hydraulic forces
GSM

¾” overcome the nip the line transitions into a steep incline.

The wider the nip the lower on the graph the curve is
10% 100%
Pick-up Speed
generated.

The gravure coater requires the rubber

rolls to be undercut slightly narrower than
the web width whereas in the smooth roll
method the rubber rolls are full width.
When the coating is transferred to the
web or applicator roll from the gravure cells it only needs to be
transferred at the width of the web. If the rubber is not undercut the
coating would form a flooded nip outside the area of the web and
gradually move into the web area, creating a hydraulic force that would
increase the coat weight to unacceptable levels in these areas. If the
rubber was undercut, the area outside the width of the web would
continue to travel around and back into the coating applicator. The
smooth roll coater requires a full width rubber roll to create the flooded
nip. If the nip was not flooded across the entire web, some areas would
have either too little coating or none at all. This flooded nip also requires
sling guards at the end of the rolls to catch and return into the pan any of
the slinging coating.

A nip is required between the coating rolls in all of the methods listed
above. What is a nip? A nip is the amount of contact that is generated
between the rolls when they are pressed together. The softer the rubber
durometer, the wider the nip will be with the same pressure. As the
pressure increases the nip width increases. How do you measure the nip
width? There are several methods available using RUBBER
IMPRESSION
PAPER

COVERED

carbon nip paper, aluminum foil, liquid coating and

ROLL

piece of paper, a computerized nip blanket. What all

these methods have in common is you must place TORQUE SHAFT
SHOULD BE
LEVELED

something between the two rolls before you close

them together.

In review, the coat weight control of each coater as depicted in the charts
show that the only coater that cannot adjust coat weight is the Direct
Gravure (shown as forward gravure in the illustration).
Reverse Forward Offset Smooth
Gravure Gravure Gravure Transfer
¼”
½”
GSM

GSM
GSM

GSM

¾”

50% 100% 150% 95% 100% 105% 10% 60% 100% 10% 100%
Gravure Speed Gravure Speed Gravure Speed Pick-up Speed

The smooth roll coater can control coat weight until the hydraulic force
over comes the coater nip and then the coat weight climbs dramatically.

The Gravure coaters offer excellent coat weight control and are stable
through out all line speeds but require an undercut rubber roll for each
web width. A sleeve system may be used in the rubber roll location. The
sleeve system allows the rubber undercut sleeve to be changed in less
than 15 minutes. This system still requires a sleeve for each web width.
The smooth roll coater offers coat weight control but needs adjustment
going from low to high line speeds. This is referred to as unstable, as
the line speed increases so does the amount of coating supplied. The
result is much of the coated web during speed-up and slow down is
waste. The advantage to the smooth roll coater is it only requires one
rubber roll for all web widths.

Gravure
GSM

Smooth Roll

Line Speed

The Direct Gravure coater is used primarily on substrates that are fragile,
like metalized PET or printed webs. If the roll applying the coating to
these two examples were operated in the reverse direction or at a
differential speed, then that roll could damage the print layer or pick off
the foil. Operating the roll in the forward direction with matched speeds
will apply the coating without damage. The smooth roll coater can adjust
coat weights and apply coatings without damage to the layers. The limit
on this coater is the flooded nip. This application works well on films or
coated papers, BUT on open face paper the coat weight cannot be
controlled. Passing the open faced paper through the flooded nip will
saturate the web and apply excessive coating.

Take all the parameters from this paper and create a chart, now you can
select the correct coater for your process.

Direct Reverse Offset Smooth

Coater Selection
Gravure Gravure Gravure Roll
Ability to Adjust Coat Weight No Yes Yes Yes
Ability to Coat Paper Yes Yes Yes No
Ability to Coat Film Yes Yes Yes Yes
Stable at all Line Speeds Yes Yes Yes No
Requires Under Cut Rubber Roll Yes Yes Yes No
Ability to Coat Printed Film Yes No Yes Yes
Ability to Coat Foil Yes No Yes Yes
 2006 PLACE
Conference
September 17-21
Cincinnati, Ohio

Coating Technology
for Flexible Packaging

Presented by:
Lee A. Ostness
Product Manager Coating & Drying Systems
Black Clawson Converting Machinery

Typical Products
Product Package Type
•Processed Meat •Pouches, Vacuum Packages
•Processed Cheese •Pouches, Wraps
•Fresh Red Meat •Barrier, Shrink Bags
•Bulk Liquids •Pouches, Bag in Box
•Cereal/Cake Mix •Inner Liners
•Medical Devices Films •Pouches, Thermal Formed
•Coffee •Brick Packs, Pouches
•Fresh Produce •Breathable Bags
•Snacks •Bags

Flex-Pack Components
Substrates Coatings
•PET 1-10 mil •Primers 0.04-0.4 gsm
•PE 1-8 mil •Adhesives 3.25-6.5 gsm
•Al foil 20-60 µ •PVDC 1.6-6.5 gsm
•BOPP/OPP 0.4-2 mil •Wash-coats 0.8-1.5 gsm
•CPP 1-4 mil • PVOH 0.5 gsm
•Nylon 0.4-2 mil •Lacquer 5.0 gsm
•METPET 1-10 mil •Acrylic Polyurethane 0.3 gsm
•Cellophane 0.8-1 mil •Varnish 0.02 – 0.04 gsm

1
 Typical Product Structures
PET 12.6µ PET 12.6µ
(PRINT) (PRINT)
PRIMER 0.04µ ADHESIVE 3.25 – 6.5µ
LDPE 12.6µ FOIL 6.3µ
FOIL 6.3µ PRIMER 0.04µ
LDPE (Heat Seal) 25µ LDPE 25 µ

Beverage Package Retort Package

Note: The foil is a barrier layer and may be substituted with METPET, Nylon, or EVOH
depending on the amount or type of barrier layer needed.

COATER/DRYER
Coater
Smooth roll
Backing Roll not Undercut
Pan Fed
Direct Gravure
Backing Roll Undercut
Sleeve
Pan Fed
Enclosed Applicator
Dryer
Air Floatation Nozzles
Roll Support

2
FLEX-PACK COATERS

Direct Reverse Offset Smooth

Gravure Gravure Gravure Roll

Methodology of Application

Gravure Coater Smooth Roll Coater

Gravure Engraved Patterns

3
 Volume
“BCM”
Billion Cubic Microns
The formula is based on
ink technology. Many of
today's coatings are of
an unique composition.
Use this formula for a
better understanding of
how the cell volumes are
achieved. Coat weights
may vary when different
coatings are applied with
the same cell volume.

formula from Consolidated Engravers

DIRECT GRAVURE: is 80 % of what the chart displays

REVERSE GRAVURE: is generally 80% of Direct Gravure
DIFFERENTIAL OFFSET GRAVURE: is generally 25% of Direct Gravure

ENGRAVING COATING CHART

WEIGHT IN POUNDS DRY SOLIDS PER REAM - 432,000 SQUARE INCHES
WEIGHT OF MATERIAL 8 LBS. PER GALLON IN SOLUTION

CHART #1 PYRAMID CELL CHART #2 QUADRANGULAR CELL CHART #3 TRI-HELICAL CELL

CELL 5% 15% 25% 35% 45% CELL 5% 15% 25% 35% 45% 50% 5% 15% 25% 35% 45% 50% CHARTS REFERENCED FROM:
NUMBER VOLUME NUMBER VOLUME NUMBER CELL DEPTH VOLUME
DEPTH SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS DEPTH SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS PAMARCO, INC.
200 0.0008 2.6 0.21 0.26 0.32 0.47 0.70 200 0.0012 5.7 0.22 0.32 0.48 0.71 1.05 1.31 120 0.0022 18.0 0.64 0.95 1.40 2.07 3.07 3.80 ARC INDUSTRIES, INC.
180 0.0009 3.2 0.23 0.29 0.36 0.53 0.79 190 0.0015 7.5 0.27 0.40 0.60 0.89 1.31 1.63 110 0.0025 20.3 0.73 1.08 1.60 2.37 3.51 4.35 AMERICAN ENGRAVING AND MACHINE CO.
165 0.0010 3.4 0.26 0.32 0.40 0.59 0.88 180 0.0018 9.4 0.33 0.48 0.72 1.07 1.58 1.96 95 0.0032 26.2 0.94 1.39 2.05 3.03 4.49 5.57 MODERN ENGRAVING AND MACHINE CO.
150 0.0020 7.5 0.51 0.64 0.80 1.18 1.75 165 0.0022 10.9 0.30 0.49 0.80 1.30 1.93 2.39 90 0.0035 28.8 1.03 1.52 2.25 3.33 4.93 6.11
142 0.0022 8.2 0.56 0.70 0.88 1.30 1.92 150 0.0025 13.3 0.46 0.68 1.00 1.48 2.19 2.72 84 0.0039 32.3 1.14 1.69 2.50 3.70 5.48 6.79
132 0.0025 9.7 0.64 0.80 1.00 1.48 2.19 140 0.0028 15.0 0.51 0.76 1.12 1.66 2.45 3.05 79 0.0040 32.7 1.18 1.75 2.58 3.81 5.64 6.99 NOTE: THIS IS FOR CHROME PLATED GRAVURE ROLLS ONLY !
120 0.0030 11.0 0.77 0.96 1.20 1.78 2.63 130 0.0030 16.0 0.55 0.81 1.20 1.78 2.63 3.26 72 0.0045 36.8 1.32 1.95 2.88 4.26 6.30 7.81 1. DETERMINE SOLIDS
116 0.0032 11.9 0.81 1.02 1.28 1.89 2.80 120 0.0032 17.2 0.59 0.87 1.28 1.89 2.80 3.48 64 0.0051 41.8 1.50 2.22 3.28 4.85 7.18 8.89 2. DETERMINE TYPE OF GRAVURE COATER
108 0.0033 12.2 0.85 1.06 1.32 1.95 2.89 110 0.0039 21.4 0.71 1.05 1.56 2.31 3.42 4.24 59 0.0055 45.0 1.61 2.39 3.53 5.22 7.73 9.57 3. DETERMINE TYPE OF GRAVURE CELL
100 0.0035 13.9 1.03 1.20 1.40 2.07 3.07 96 0.0044 26.3 0.80 1.19 1.76 2.61 3.85 4.79 54 0.0060 49.0 1.76 2.60 3.85 5.70 8.44 10.46 4. FIND THE DESIRED COATWEIGHT IN THE CHART
90 0.0038 16.0 0.98 1.22 1.52 2.25 3.33 85 0.0049 30.0 0.90 1.32 1.96 2.90 4.29 5.33 50 0.0065 53.3 1.91 2.83 4.18 6.18 9.15 11.34
80 0.0040 17.3 1.02 1.28 1.60 2.37 3.50 75 0.0054 32.0 0.98 1.46 2.16 3.20 4.73 5.88 45 0.0073 59.6 2.14 3.17 4.68 6.92 10.25 12.70 5. TRACE THAT ROLL OVER TO THE VOLUME IN THE SAME CHART
70 0.0045 18.0 1.15 1.44 1.80 2.66 3.94 65 0.0060 35.4 1.10 1.62 2.40 3.55 5.26 6.53 42 0.0075 61.5 2.19 3.25 4.80 7.10 10.52 13.04 6. CHOOSE THE ROLL FROM ANY VENDOR CHART THAT
65 0.0050 20.4 1.28 1.60 2.00 2.96 4.38 55 0.0065 40.4 1.19 1.76 2.60 3.85 5.69 7.07 36 0.0090 73.3 2.64 3.91 5.78 8.55 12.66 15.68 MATCHES THE VOLUME AND CELL TYPE.
60 0.0058 24.4 1.49 1.86 2.32 3.43 5.08 45 0.0068 44.5 1.24 1.84 2.72 4.03 5.96 7.40 35 0.0093 76.0 2.80 4.09 5.98 8.74 13.10 16.23
55 0.0062 26.6 1.58 1.98 2.48 3.67 5.43 35 0.0070 46.6 1.28 1.89 2.80 4.14 6.13 7.62 33 0.0096 78.2 2.81 4.16 6.15 9.10 13.48 16.70
50 0.0076 33.7 1.94 2.42 3.02 4.47 6.61 30 0.0090 58.7 1.64 2.43 3.60 5.33 7.88 9.79 28 0.0110 90.0 3.22 4.77 7.05 10.43 15.45 19.15
45 0.0090 41.0 2.30 2.88 3.60 5.33 7.88 25 0.0120 81.0 2.19 3.25 4.80 7.10 10.51 13.06 26 0.0130 106.5 3.81 5.63 8.33 12.32 18.25 22.61
40 0.0104 48.0 2.67 3.33 4.16 6.15 9.11 16 0.0170 117.0 3.11 4.60 6.80 10.06 14.89 16.50 24 0.0140 115.0 4.09 6.05 8.95 13.24 19.62 24.31

DIRECT FORWARD GRAVURE DIRECT FORWARD GRAVURE DIRECT FORWARD GRAVURE DIRECT FORWARD GRAVURE
CHART #4 PYRAMID CELL CHART #5 QUADRANGULAR CELL CHART #6 QUADRANGULAR CHANNELED CELL CHART #7 TRI-HELICAL CELL
CELL 5% 15% 25% 35% 45% CELL 5% 15% 25% 35% 45% 50% 5% 15% 25% 35% 45% 50% 5% 15% 25% 35% 45% 50%
VOLUME VOLUME CELL DEPTH VOLUME CELL DEPTH VOLUME
DEPTH SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS DEPTH SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS
0.0008 2.6 0.17 0.21 0.26 0.38 0.56 0.0012 5.7 0.18 0.26 0.38 0.57 0.84 1.05 0.0012 5.7 0.20 0.30 0.44 0.65 0.97 1.21 0.0022 18.0 0.51 0.76 1.12 1.66 2.46 3.04
0.0009 3.2 0.19 0.23 0.29 0.42 0.63 0.0015 7.5 0.22 0.32 0.48 0.71 1.05 1.30 0.0015 7.5 0.25 0.37 0.55 0.82 1.21 1.50 0.0025 20.3 0.58 0.86 1.28 1.90 2.81 3.48
0.0010 3.4 0.20 0.26 0.32 0.47 0.70 0.0018 9.4 0.26 0.39 0.58 0.86 1.26 1.57 0.0018 9.4 0.30 0.45 0.66 0.98 1.45 1.80 0.0032 26.2 0.75 1.11 1.64 2.42 3.59 4.46
0.0020 7.5 0.41 0.51 0.64 0.94 1.40 0.0022 10.9 0.24 0.39 0.64 1.04 1.54 1.91 0.0022 10.9 0.28 0.45 0.74 1.20 1.78 2.20 0.0035 28.8 0.82 1.22 1.80 2.66 3.94 4.89
0.0022 8.2 0.45 0.56 0.70 1.04 1.54 0.0025 13.3 0.37 0.54 0.80 1.18 1.75 2.18 0.0025 13.3 0.42 0.62 0.92 1.36 2.01 2.50 0.0039 32.3 0.91 1.35 2.00 2.96 4.38 5.43
0.0025 9.7 0.51 0.64 0.80 1.18 1.75 0.0028 15.0 0.41 0.60 0.90 1.33 1.96 2.44 0.0028 15.0 0.47 0.70 1.03 1.53 2.25 2.81 0.0040 32.7 0.95 1.40 2.06 3.05 4.51 5.59
0.0030 11.0 0.61 0.77 0.96 1.42 2.10 0.0030 16.0 0.44 0.65 0.96 1.42 2.10 2.61 0.0030 16.0 0.50 0.74 1.10 1.64 2.42 3.00 0.0045 36.8 1.05 1.56 2.30 3.41 5.04 6.25
0.0032 11.9 0.65 0.82 1.02 1.51 2.24 0.0032 17.2 0.47 0.69 1.02 1.51 2.24 2.78 0.0032 17.2 0.54 0.80 1.18 1.74 2.58 3.20 0.0051 41.8 1.20 1.77 2.62 3.88 5.74 7.11
0.0033 12.2 0.68 0.85 1.06 1.56 2.31 0.0039 21.4 0.57 0.84 1.25 1.85 2.74 3.39 0.0039 21.4 0.65 0.97 1.44 2.13 3.15 3.90 0.0055 45.0 1.29 1.91 2.82 4.18 6.18 7.66
0.0035 13.9 0.82 0.96 1.12 1.66 2.46 0.0044 26.3 0.64 0.95 1.41 2.09 3.08 3.83 0.0044 26.3 0.74 1.09 1.62 2.40 3.54 4.41 0.0060 49.0 1.41 2.08 3.08 4.56 6.75 8.37
0.0038 16.0 0.78 0.98 1.22 1.80 2.66 0.0049 30.0 0.72 1.06 1.57 2.32 3.43 4.26 0.0049 30.0 0.82 1.22 1.80 2.67 3.95 4.90 0.0065 53.3 1.53 2.26 3.34 4.94 7.32 9.07
0.0040 17.3 0.82 1.02 1.28 1.90 2.80 0.0054 32.0 0.79 1.17 1.73 2.56 3.78 4.70 0.0054 32.0 0.91 1.34 1.99 2.94 4.35 5.41 0.0073 59.6 1.71 2.53 3.74 5.54 8.20 10.16
0.0045 18.0 0.92 1.15 1.44 2.13 3.15 0.0060 35.4 0.88 1.30 1.92 2.84 4.21 5.22 0.0060 35.4 1.01 1.49 2.21 3.27 4.84 6.01 0.0075 61.5 1.76 2.60 3.84 5.68 8.42 10.43
0.0050 20.4 1.02 1.28 1.60 2.37 3.50 0.0065 40.4 0.95 1.40 2.08 3.08 4.55 5.66 0.0065 40.4 1.09 1.62 2.39 3.54 5.23 6.50 0.0090 73.3 2.11 3.13 4.62 6.84 10.13 12.54
0.0058 24.4 1.19 1.49 1.86 2.74 4.06 0.0068 44.5 0.99 1.47 2.18 3.22 4.77 5.92 0.0068 44.5 1.14 1.69 2.50 3.71 5.48 6.81 0.0093 76.0 2.24 3.27 4.78 6.99 10.48 12.98
0.0062 26.6 1.26 1.58 1.98 2.94 4.34 0.0070 46.6 1.02 1.51 2.24 3.31 4.90 6.10 0.0070 46.6 1.18 1.74 2.58 3.81 5.64 7.01 0.0096 78.2 2.25 3.33 4.92 7.28 10.78 13.36
0.0076 33.7 1.55 1.94 2.42 3.58 5.29 0.0090 58.7 1.31 1.95 2.88 4.26 6.30 7.83 0.0090 58.7 1.51 2.24 3.31 4.90 7.25 9.01 0.0110 90.0 2.58 3.81 5.64 8.34 12.36 15.32
0.0090 41.0 1.84 2.30 2.88 4.26 6.30 0.0120 81.0 1.76 2.60 3.84 5.68 8.41 10.45 0.0120 81.0 2.02 2.99 4.42 6.53 9.67 12.02 0.0130 106.5 3.05 4.51 6.66 9.86 14.60 18.09
0.0104 48.0 2.13 2.66 3.33 4.92 7.29 0.0170 117.0 2.49 3.68 5.44 8.05 11.91 13.20 0.0170 117.0 2.86 4.23 6.26 9.26 13.70 15.18 0.0140 115.0 3.27 4.84 7.16 10.59 15.70 19.45

DIRECT REVERSE GRAVURE DIRECT REVERSE GRAVURE DIRECT REVERSE GRAVURE DIRECT REVERSE GRAVURE
CHART #8 PYRAMID CELL CHART #9 QUADRANGULAR CELL CHART #10 QUADRANGULAR CHANNELED CELL CHART #11 TRI-HELICAL CELL
CELL 5% 15% 25% 35% 45% CELL 5% 15% 25% 35% 45% 50% 5% 15% 25% 35% 45% 50% 5% 15% 25% 35% 45% 50%
VOLUME VOLUME CELL DEPTH VOLUME CELL DEPTH VOLUME
DEPTH SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS DEPTH SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS
0.0008 2.6 0.14 0.17 0.20 0.30 0.45 0.0012 5.7 0.14 0.21 0.31 0.45 0.67 0.84 0.0012 5.7 0.16 0.24 0.35 0.52 0.77 0.96 0.0022 18.0 0.41 0.61 0.90 1.32 1.96 2.43
0.0009 3.2 0.15 0.19 0.23 0.34 0.51 0.0015 7.5 0.17 0.26 0.38 0.57 0.84 1.04 0.0015 7.5 0.20 0.30 0.44 0.66 0.96 1.20 0.0025 20.3 0.47 0.69 1.02 1.52 2.25 2.78
0.0010 3.4 0.16 0.20 0.26 0.38 0.56 0.0018 9.4 0.21 0.31 0.46 0.68 1.01 1.25 0.0018 9.4 0.24 0.36 0.53 0.79 1.16 1.44 0.0032 26.2 0.60 0.89 1.31 1.94 2.87 3.56
0.0020 7.5 0.33 0.41 0.51 0.76 1.12 0.0022 10.9 0.19 0.32 0.51 0.83 1.24 1.53 0.0022 10.9 0.22 0.36 0.59 0.96 1.42 1.76 0.0035 28.8 0.66 0.97 1.44 2.13 3.16 3.91
0.0022 8.2 0.36 0.45 0.56 0.83 1.23 0.0025 13.3 0.29 0.43 0.64 0.95 1.40 1.74 0.0025 13.3 0.34 0.50 0.74 1.09 1.61 2.00 0.0039 32.3 0.73 1.08 1.60 2.37 3.51 4.35
0.0025 9.7 0.41 0.51 0.64 0.95 1.40 0.0028 15.0 0.33 0.48 0.72 1.06 1.57 1.95 0.0028 15.0 0.38 0.56 0.82 1.22 1.80 2.24 0.0040 32.7 0.76 1.12 1.65 2.44 3.61 4.47
0.0030 11.0 0.49 0.61 0.77 1.14 1.68 0.0030 16.0 0.35 0.52 0.77 1.14 1.68 2.09 0.0030 16.0 0.40 0.60 0.88 1.31 1.94 2.40 0.0045 36.8 0.84 1.25 1.84 2.73 4.03 5.00
0.0032 11.9 0.52 0.65 0.82 1.21 1.79 0.0032 17.2 0.38 0.55 0.82 1.21 1.79 2.23 0.0032 17.2 0.43 0.64 0.94 1.39 2.06 2.56 0.0051 41.8 0.96 1.42 2.10 3.10 4.60 5.69
0.0033 12.2 0.54 0.68 0.84 1.25 1.85 0.0039 21.4 0.46 0.67 1.00 1.48 2.19 2.71 0.0039 21.4 0.52 0.78 1.15 1.70 2.52 3.12 0.0055 45.0 1.03 1.53 2.26 3.34 4.95 6.12
0.0035 13.9 0.66 0.77 0.90 1.32 1.96 0.0044 26.3 0.51 0.76 1.13 1.67 2.46 3.07 0.0044 26.3 0.59 0.87 1.30 1.92 2.83 3.53 0.0060 49.0 1.12 1.66 2.46 3.65 5.40 6.69
0.0038 16.0 0.63 0.78 0.97 1.44 2.13 0.0049 30.0 0.57 0.85 1.25 1.86 2.75 3.41 0.0049 30.0 0.66 0.97 1.44 2.13 3.16 3.92 0.0065 53.3 1.22 1.81 2.68 3.96 5.86 7.26
0.0040 17.3 0.66 0.82 1.02 1.52 2.24 0.0054 32.0 0.63 0.93 1.38 2.05 3.03 3.76 0.0054 32.0 0.72 1.07 1.59 2.36 3.48 4.33 0.0073 59.6 1.37 2.03 3.00 4.43 6.56 8.13
0.0045 18.0 0.74 0.92 1.15 1.70 2.52 0.0060 35.4 0.70 1.04 1.54 2.27 3.37 4.18 0.0060 35.4 0.81 1.19 1.77 2.61 3.87 4.81 0.0075 61.5 1.40 2.08 3.07 4.54 6.73 8.35
0.0050 20.4 0.82 1.02 1.28 1.89 2.80 0.0065 40.4 0.76 1.12 1.66 2.46 3.64 4.52 0.0065 40.4 0.87 1.29 1.91 2.83 4.19 5.20 0.0090 73.3 1.69 2.50 3.70 5.47 8.10 10.04
0.0058 24.4 0.95 1.19 1.48 2.20 3.25 0.0068 44.5 0.79 1.17 1.74 2.58 3.81 4.74 0.0068 44.5 0.91 1.35 2.00 2.97 4.39 5.45 0.0093 76.0 1.79 2.62 3.83 5.59 8.38 10.39
0.0062 26.6 1.01 1.27 1.59 2.35 3.48 0.0070 46.6 0.82 1.21 1.79 2.65 3.92 4.88 0.0070 46.6 0.94 1.39 2.06 3.05 4.51 5.61 0.0096 78.2 1.80 2.66 3.94 5.82 8.63 10.69
0.0076 33.7 1.24 1.55 1.93 2.86 4.23 0.0090 58.7 1.05 1.56 2.30 3.41 5.04 6.27 0.0090 58.7 1.21 1.79 2.65 3.92 5.80 7.21 0.0110 90.0 2.06 3.05 4.51 6.68 9.89 12.26
0.0090 41.0 1.47 1.84 2.30 3.41 5.04 0.0120 81.0 1.40 2.08 3.07 4.54 6.73 8.36 0.0120 81.0 1.61 2.39 3.53 5.23 7.74 9.61 0.0130 106.5 2.44 3.60 5.33 7.88 11.68 14.47
0.0104 48.0 1.71 2.13 2.66 3.94 5.83 0.0170 117.0 1.99 2.94 4.35 6.44 9.53 10.56 0.0170 117.0 2.29 3.38 5.00 7.40 10.96 12.14 0.0140 115.0 2.62 3.87 5.73 8.47 12.56 15.56

OFFSET GRAVURE OFFSET GRAVURE OFFSET GRAVURE OFFSET GRAVURE

CHART #12 PYRAMID CELL CHART #13 QUADRANGULAR CELL CHART #14 QUADRANGULAR CHANNELED CELL CHART #15 TRI-HELICAL CELL
CELL 5% 15% 25% 35% 45% CELL 5% 15% 25% 35% 45% 50% 5% 15% 25% 35% 45% 50% 5% 15% 25% 35% 45% 50%
VOLUME VOLUME CELL DEPTH VOLUME CELL DEPTH VOLUME
DEPTH SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS DEPTH SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS SOLIDS
0.0008 2.6 0.06 0.07 0.08 0.12 0.18 0.0012 5.7 0.06 0.09 0.13 0.19 0.28 0.35 0.0012 5.7 0.07 0.10 0.15 0.22 0.32 0.40 0.0022 18.0 0.17 0.25 0.37 0.55 0.81 1.00
0.0009 3.2 0.06 0.08 0.10 0.14 0.21 0.0015 7.5 0.07 0.11 0.16 0.23 0.35 0.43 0.0015 7.5 0.08 0.12 0.18 0.27 0.40 0.49 0.0025 20.3 0.19 0.29 0.42 0.63 0.93 1.15
0.0010 3.4 0.07 0.08 0.11 0.16 0.23 0.0018 9.4 0.09 0.13 0.19 0.28 0.42 0.52 0.0018 9.4 0.10 0.15 0.22 0.32 0.48 0.60 0.0032 26.2 0.25 0.37 0.54 0.80 1.19 1.47
0.0020 7.5 0.14 0.17 0.21 0.31 0.46 0.0022 10.9 0.08 0.13 0.21 0.34 0.51 0.63 0.0022 10.9 0.09 0.15 0.24 0.39 0.59 0.73 0.0035 28.8 0.27 0.40 0.59 0.88 1.30 1.61
0.0022 8.2 0.15 0.18 0.23 0.34 0.51 0.0025 13.3 0.12 0.18 0.26 0.39 0.58 0.72 0.0025 13.3 0.14 0.21 0.30 0.45 0.66 0.83 0.0039 32.3 0.30 0.45 0.66 0.98 1.45 1.79
0.0025 9.7 0.17 0.21 0.26 0.39 0.58 0.0028 15.0 0.13 0.20 0.30 0.44 0.65 0.81 0.0028 15.0 0.15 0.23 0.34 0.50 0.74 0.93 0.0040 32.7 0.31 0.46 0.68 1.01 1.49 1.85
0.0030 11.0 0.20 0.25 0.32 0.47 0.69 0.0030 16.0 0.14 0.21 0.32 0.47 0.69 0.86 0.0030 16.0 0.17 0.25 0.36 0.54 0.80 0.99 0.0045 36.8 0.35 0.51 0.76 1.12 1.66 2.06
0.0032 11.9 0.21 0.27 0.34 0.50 0.74 0.0032 17.2 0.15 0.23 0.34 0.50 0.74 0.92 0.0032 17.2 0.18 0.26 0.39 0.57 0.85 1.06 0.0051 41.8 0.40 0.59 0.87 1.28 1.90 2.35
0.0033 12.2 0.22 0.28 0.35 0.51 0.76 0.0039 21.4 0.19 0.28 0.41 0.61 0.90 1.12 0.0039 21.4 0.22 0.32 0.47 0.70 1.04 1.29 0.0055 45.0 0.43 0.63 0.93 1.38 2.04 2.53
0.0035 13.9 0.27 0.32 0.37 0.55 0.81 0.0044 26.3 0.21 0.31 0.46 0.69 1.02 1.26 0.0044 26.3 0.24 0.36 0.53 0.79 1.17 1.45 0.0060 49.0 0.46 0.69 1.02 1.50 2.23 2.76
0.0038 16.0 0.26 0.32 0.40 0.59 0.88 0.0049 30.0 0.24 0.35 0.52 0.77 1.13 1.41 0.0049 30.0 0.27 0.40 0.60 0.88 1.30 1.62 0.0065 53.3 0.50 0.75 1.10 1.63 2.42 2.99
0.0040 17.3 0.27 0.34 0.42 0.63 0.92 0.0054 32.0 0.26 0.38 0.57 0.84 1.25 1.55 0.0054 32.0 0.30 0.44 0.66 0.97 1.44 1.79 0.0073 59.6 0.57 0.84 1.24 1.83 2.71 3.35
0.0045 18.0 0.30 0.38 0.48 0.70 1.04 0.0060 35.4 0.29 0.43 0.63 0.94 1.39 1.72 0.0060 35.4 0.33 0.49 0.73 1.08 1.60 1.98 0.0075 61.5 0.58 0.86 1.27 1.87 2.78 3.44
0.0050 20.4 0.34 0.42 0.53 0.78 1.16 0.0065 40.4 0.31 0.46 0.69 1.02 1.50 1.87 0.0065 40.4 0.36 0.53 0.79 1.17 1.73 2.15 0.0090 73.3 0.70 1.03 1.53 2.26 3.34 4.14
0.0058 24.4 0.39 0.49 0.61 0.91 1.34 0.0068 44.5 0.33 0.48 0.72 1.06 1.57 1.95 0.0068 44.5 0.38 0.56 0.83 1.22 1.81 2.25 0.0093 76.0 0.74 1.08 1.58 2.31 3.46 4.28
0.0062 26.6 0.42 0.52 0.65 0.97 1.43 0.0070 46.6 0.34 0.50 0.74 1.09 1.62 2.01 0.0070 46.6 0.39 0.57 0.85 1.26 1.86 2.31 0.0096 78.2 0.74 1.10 1.62 2.40 3.56 4.41
0.0076 33.7 0.51 0.64 0.80 1.18 1.75 0.0090 58.7 0.43 0.64 0.95 1.41 2.08 2.58 0.0090 58.7 0.50 0.74 1.09 1.62 2.39 2.97 0.0110 90.0 0.85 1.26 1.86 2.75 4.08 5.06
0.0090 41.0 0.61 0.76 0.95 1.41 2.08 0.0120 81.0 0.58 0.86 1.27 1.87 2.77 3.45 0.0120 81.0 0.67 0.99 1.46 2.16 3.19 3.97 0.0130 106.5 1.01 1.49 2.20 3.25 4.82 5.97
0.0104 48.0 0.70 0.88 1.10 1.62 2.41 0.0170 117.0 0.82 1.21 1.80 2.66 3.93 4.36 0.0170 117.0 0.94 1.40 2.06 3.05 4.52 5.01 0.0140 115.0 1.08 1.60 2.36 3.50 5.18 6.42

4
DIRECT GRAVURE

BACKING; LINESPEED
Undercut Required

BACKING/GRAVURE = 3/8” NIP

GRAVURE; 90% to 110% LINESPEED

USUALLY REQUIRES POST SMOOTHING

REVERSE GRAVURE

BACKING; LINESPEED
Undercut required

BACKING/GRAVURE = 3/8” NIP

GRAVURE; 50% to 150% OF LINESPEED

OFFSET GRAVURE

BACKING; LINESPEED

BACKING/OFFSET =3/8” NIP

OFFSET; 95% to 105% OF LINESPEED

Undercut Required

OFFSET/GRAVURE = 3/8” NIP

GRAVURE; 10% to 25% OF LINESPEED

5
 SMOOTH ROLL

BACKING; LINESPEED
NO Undercut Required

BACKING/PICKUP = VARY NIP

PICKUP;20% to 150% LINESPEED

COAT WEIGHT
NIP WIDTH & ROLL SPEED
•Coat weight control is dependent upon the relationship of
linespeed vs. nip width and pickup roll speed
•By increasing pickup roll speed the coat weight increases
•By decreasing the pickup roll footprint the coat weight
increases Roll vs. Speed

•Other coat weight variables

3/8" nip

–coating solids 1/2" nip

Coatweight

3/4" nip
–coating viscosity

Roll spee d

Transfer Roll Coater

CHECKING NIP
IMPRESSIONS
RUBBER
COVERED
ROLL
FOOTPRINT

LOAD

STEEL ROLL

6
 Coat Weight Curves
Reverse Forward Offset Smooth
Gravure Gravure Gravure Transfer
¼”
½”
GSM

GSM
GSM

GSM ¾”

50% 100% 150% 95% 100% 105% 10% 60% 100% 10% 100%
Gravure Speed Gravure Speed Gravure Speed Pick-up Speed

Factors That Affect Coat Weight

•Gravure Volume •Roll Speed
•Coating Solids •Coating Viscosity
•Nip Width

COAT WEIGHT STABILITY

•Effects of speed on coatweight
–Differential Offset Gravure - STABLE
–Direct/Reverse Gravure - STABLE
–Smooth Roll - UNSTABLE

Gravure
GSM

Smooth Roll

Line Speed

Coater Direct Reverse Offset Smooth

Selection Gravure Gravure Gravure Roll
Ability to Adjust
No Yes Yes Yes
Coat Weight
Ability to Coat
Yes Yes Yes No
Paper
Ability to Coat
Yes Yes Yes Yes
Film
Stable at All Line
Yes Yes Yes No
Speeds
Requires Undercut
Yes Yes Yes No
Rubber Roll
Ability to Coat
Yes No Yes Yes
Printed Film

Ability to Coat Foil Yes No Yes Yes

7
Thank You
PRESENTED BY

Lee A. Ostness
Product Manager Coating & Drying Systems
Black Clawson Converting Machinery
ostnessl@bc-egan.com

Please remember to turn

in your evaluation sheet...