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BOBST - Coating lines

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The specialty coating market can be best described as both segmented and specialized. With over 50 years of experience in this industry, BOBST is uniquely placed to handle projects that demand a high level of customization.
BOBST's coating product line has specialist engineering know-how and understanding covering the wide range of process technologies involved, making it perfectly placed to supply users with equipment featuring the highest and most consistent performance.

ROTOSIL
ROTOMELT
ROTOCOAT
 

Coating process

The coating process consists of applying a coating material to a moving web of flexible substrate.
The carrier substrate may be paper, film, or aluminum foil and the resulting material's additional properties will vary depending on the required application and on the material’s end-use.
The benefit of coating is that it delivers to the substrate enhanced aesthetic and physical properties derived from the coating material.

Coating types

In flexible packaging, the most common types of coating are:
  • Varnish: to impart a clear, glossy surface to the web
  • Cold seal: used mainly for products where normal heat sealing cannot be used (chocolate bars, ice-creams, etc)
  • PVdC coating: used to improve the barrier properties of transparent films, as well as the gloss of printed films
 

Coating lines and applications

These types of coating are usually applied in-line with a printing press by dedicated units or off-line by coating-laminating machines. Special coatings are also used in industries other than flexible packaging. These applications may include the production of labelstock material, release liner paper and films, as well as a great variety of pressure sensitive adhesive tapes or laminates used in the medical field or in industrial applications.
Different types of coating line may be found in each industry, but broadly speaking each system is based on a roll design and will consist of a metering system for applying the coating material to the substrate, followed by a drying tunnel to dry the coated web before it is rewound. Specialty coating lines can be custom built in order to satisfy a variety of different market requirements.
 

BOBST expertise and knowledge

From its vast expertise in designing and manufacturing both regular and special coating lines, BOBST's Rotomec product line can provide systems for the application of every kind of packaging coating, along with the production of pressure sensitive adhesive tapes and labels such as packaging tapes, reinforced tapes, masking tapes, double sided tapes, special tapes, release paper, and labelstock.
 

Processed materials


Paper
Paper is a fibre-based material produced from wood, rags or organic material. The types of paper used in the packaging and graphic arts industries typically use wood and/or recycled paper and board, which is then chemically or mechanically processed to produce cellulose pulp. This pulp is bleached and processed in a paper making machine to produce reels of paper which may optionally be coated or finished to provide a better surface and/or improved visual appearance.
Paper may be between 0.07 mm and 0.18mm thick, with paper for printing and packaging applications generally being in a range between 60 and 120 gsm. The crossover point between paper and board is normally considered to be around 160 grams per square meter (gsm), as it is only at this level that a fibrous material is likely to be stiff and rigid enough to make a container.
Paper has a wide range of industrial applications including use for the packaging of products as diverse as confectionery and cigarettes, as a component in packaging laminates, and for many commercial print uses.
 
Carton board
Carton board (also called cardboard, paperboard or solid board) is the name for a range of paper based materials that includes folding box board (FBB, GC or UC), solid bleached board (SBB, SBS, or GZ), solid unbleached board (SUB or SUS), white lined chipboards (WLC, GD, GT, or UD), some unlined chipboards, and certain laminated boards.
To manufacture carton board, fibrous material, either from trees, recycled paper, or a mixture of the two, is turned into pulp. It is then bleached and processed in a board making machine to create a board consisting of one or more layers, which may optionally be coated to provide a better surface and/or improved visual appearance.
The crossover point between paper and board is normally considered to be around 160 grams per square meter (gsm), as it is only at this level that a fibrous material is likely to be stiff and rigid enough to make a container.
Cartonboard is primarily used in the packaging industry to produce all types of folding cartons, but may also be used for graphics applications. For folding cartons the board used will normally be in the range 200 to 600gsm, or 350 to 800 microns.
 
Film
A film is usually characterized as a thin synthetic resin layer. There are many types of films and their use depends on their physical and chemical properties, which make them especially suitable for a given application.
The most commonly used plastic films are low density polyethylene (LDPE), Polypropylene (PP), bioriented polypropylene (BOPP), and polyester (PET).
Printed film is used for packaging, display materials, stickers, seals, and a wide range of other graphic applications.
Films are generally characterized by their basis weight, expressed in g/m²; and thickness, expressed in microns. For some films it is also useful to know their density, expressed in g/cm3.
The increasing awareness of environmental issues is intensifying research into film substrates derived from renewable sources that are compostable. 
 
Aluminium foil
Aluminum is produced from bauxite, an ore abundant in nature. From the rolling mill, aluminum foils emerge with a natural shiny finish, almost as bright as a mirror, but also can be produced with an as-rolled, satin-like finish called matte.
Aluminum foil has all of the unique functional characteristics of the aluminum alloy from which it is made.
Because of its exceptional barrier properties, aluminum foil is used across a wide range of flexible and other packaging applications to protect foods, drugs, cosmetics, and a lengthy list of other items, most often in combination with other packaging materials.
 
Laminates
A laminate is a material that can be constructed by bringing two or more layers of material together. This can include different material combinations from a wide spectrum of flexible substrates including thin aluminum foil, film, and paper. These materials have different physical properties and varying thicknesses that combine to provide the required barrier performance.
Converted single- or multi-layer webs are used in a number of industries, from the packaging of food and non-food products to industrial applications including the photovoltaic industry.

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