Contract coaters, also called toll coaters, provide web-coating and converting services to assist other companies in the development and manufacture of web-coated products. Typically, they have extensive process facilities to accomplish this task. They have coating methods that can coat a wide range of coating weights using both aqueous and solvent based formulations. Facilities include pilot and manufacturing coaters, solution preparation facilities and quality and analytical testing. These services are available on a fee basis.
The following is additional detail of some of the available process components:
Coating methods
Slot Die, Reverse Roll, Forward Roll, Reverse Gravure, Direct Gravure, Mayer Rod, Knife over Roll, Polishing Bar, Multi-Layer, Slide, Curtain, Metalizing, Solvent & Aqueous coating & drying capability.
Other Services
Laminating, Compounding, Slitting, Sheeting, packaging, Manufacturing coaters, Pilot Coaters, Surface treatment, web handling for a variety of substrates.
They are several reasons to consider using toll coaters. Often companies do not have the appropriate coating process hardware and technology to scale-up and manufacture a commercial product and product development and commercialization can be hampered. This can apply to companies who are developing new product concepts and only have laboratory-coating facilities. Toll coating can be a fast inexpensive route to demonstrating the product on a coating line that can produce commercial quality product for evaluation. Several coating methods can be evaluated to select he optimum method. It will give realistic appraisal of the feasibility of making the product on a commercial coating line and obtaining an estimate of the cost of manufacture, which is key need for new products, If successful then there is a source of product which can provide product for sale.
The alternate approach of purchasing and installing the necessary pilot and production hardware can be expensive and time consuming. In addition, the basic design data may not be available since there are no pilot test facilities to develop basic date for the new coating line. Also there may not be capital resources available for this. Often, it is more cost effective to continue contract manufacturing.
Another reason is that companies with existing coating lines may not have the optimum coating methods to coat new products and to increase coater line speed. Every coating method has a region of optimum coatability where defect free product can be made. The new product requirements may make the current method ineffective and require a new method is required for optimum operation. Forcing the product to use the current methods can reduce yield and quality. Using toll coaters will permit the rapid selection and demonstration of the best coating method, so that existing coaters can be upgraded,
Another situation where contract coaters are effective is when current capacity limits have been reached and additional capacity is needed. Contract coaters can rapidly provide the needed capacity until decision is made to add additional. Also if the increase is temporary, minimal resources have been expended.
The individual contract coaters specialize in certain aspects of the converting process and often do not have the complete range of services. To locate contract coaters and their specific capabilities, there are two directories available on PFFC Website and the AIMCAL Website.
Lab/Pilot/Technical Facilities Directory
http://pffc-online.com/coat_lam/main/lab-pilot-technical-facilities-directory-1110/
The AIMCAL Source Book, also has listing of contract coaters:
http://www.aimcal.org/sourcebook/aimcal-sourcebook.aspx