Web Coating

The typical coating line is a complex process that consists of 17 major components, table 1, each of which has many subsystems, that are necessary for the successful operation and can a cause defects if not functioning as specified.  The total number depends on the exact design of the coating line. A typical coater can contain at least 300 separate equipment modules that need to be controlled and measured, to run successfully with good quality and costs.

It would simplify the operation of the coater if a few of these modules could be identified as being of major importance and these were the prime focus of operating the coating line.  However; all of them all important and a malfunction or an incorrect setting of an apparent trivial module can lead to problems, Therefore, each of these modules must be correctly set and monitored throughout a coating campaign. When the overall volume produced changes from a few high volume products to many lower volume products, it is essential that when the product is changed that correct settings

 A simple, basic and inexpensive method of insuring that all modules are functioning at the right conditions is to prepare and use Standard Operating Procedures for all product and process modules. These should be used as part of an ongoing training program for operating personnel. Also they should be monitored and modified as needed. If a defect is traced to a specific module, the procedure should be changed to insure no further occurrence.