1. Gravure Coating: Webinar April 26, 2012 John Looser New Era Converting Machinery P.O. Box 377 Hawthorne, NJ 07506 Phone: 973-413-4605 E-mail: john.looser@neweraconverting.comwww.neweraconverting.com 1 One of the Most Versatile Methods in the Industry

2. Webinar Outline Classic Gravure Coater Section Details Improvements Enclosed Applicator Sleeve System Cartridge Systems Variations Reverse Gravure Offset Gravure Differential Offset Gravure Process Handles: 2-Roll and 3-Roll Gravure Pressurized Gravure Two-side Coating Versatility Application Range Coating Types Products 2 3. Classic Gravure Coater Sections: Coating Reservoir (Pan) Gravure Roll (Etched Metal) Doctor Blade Impression Roll (Rubber) Process: Coating Pick-up Fill Cells Wipe (Doctor) Excess Transfer Coating Empty Cells (Transfer Efficiency) Film Split Impression / Back-up Roll Gravure Roll Doctor Blade Coating Pan Coated Web Incoming Web 3 4. Classic Gravure Coater Impression / Back-up Roll Gravure Roll Doctor Blade Coating Pan Coated Web Incoming Web 4 Terminology: Direct Gravure Forward Application Synchronous Rotation Pan Fed 5. Classic Gravure Coater Coating Reservoir Enclosed Applicator Shown Gravure Roll Motor Driven Pneumatically Positioned Doctor Blade Integral to Enclosed Applicator Impression Roll Nip/Web Driven 5 6. Coating Pan Function: Delivers Coating to Gravure Roll Maintain Constant Level Stand Pipe or Overflow Weir Consistent Coating Movement Continuous Recirculation Foam Management Avoid Solids Settling Enclosure / Covers Minimize Solvent Evaporation Contain Slinging Pneumatic Pan Lift Gravure Roll Doctor Blade Supply ReturnReturn Gravure Roll Doctor Blade Supply Return 6 7. Gravure Roll Function: Deliver Consistent Coating Homogeneous Transfer (Across and Down Web) Etched / Patterned Cylinder Determines Coat Weight and Appearance Cell Creation: Mechanical / Laser / Electronic Driven Roll Tension Control Idle Mode Vector or Servo Controlled Cored for Temperature Control Heat Management Viscosity Control 7 8. Cell Creation Gravure Patterns Cell - Coating Reservoir BCM: Volume = Billion Cubic Micron per Square Inch 2 200 BCM LPI: Cell Density = Lines Per Inch 10 1500 LPI Release / Transfer Rate % Coating Volume Released Onto Substrate Patterns / Shapes Appearance and Flow Promote Release Methods for Cell Creation Mechanical Engraving Laser Engraving Electronic Engraving 8 9. Cell Creation Mechanical Engraving Roll Design Steel Core with Soft Copper Layer Chrome Plating Over Pattern Cell Creation Patterned Tooling Stamps/Forms Shapes Material is NOT Removed Surface is Re-Formed Roll Precision Can Be Affected Release Characteristics Most Angles are 45o High Surface Tension Average Release 40-50% 9 10. Mechanical Engraving Common Shapes 10 Quad Roto Flo Quadragravure ImprovingReleaseProperties Pyramid Roto-Flo Pyramid Tri-Helical Quad Channel 11. Cell Creation Laser Engraving Roll Design Steel Core with Ceramic Covering Cell Creation Focused Pulses Create Shape Laser Vaporizes Surface Material Release Characteristics Relatively High Surface Roughness Medium Surface Tension Average Release 50-60% 11 Multi-Hit Single-Hit 12. Laser Engraving Common Shapes 12 ImprovingReleaseProperties 30o Channel 60o Hex Tri-Helical 30o Hex 13. Cell Creation Electronic Engraving Roll Design Steel Core with Hard Copper Layer Chrome Plating Over Pattern Cell Creation Electronically Positioned Diamond Tip Stylus Material is Precisely Removed Roll Precision is Maintained Release Characteristics Low Surface Tension Average Release 65-75% 13 14. Electronic Engraving Common Shapes 14 15. Doctor Blade Function: Remove Excess Coating Coating in Cells Only Cell Determines Coat Weight Angle of Attack Trailing Blade Low Speed / Low Viscosity Hydraulic Forces Can Lift Blade Traps Contaminates Reverse Angle / Chisel / Plowing Increased Speed and Viscosity Hydraulic Force Helps Hold Blade Rejects Contaminates Loading Pressure 0.5 4.0 pli Gravure Roll Coating Pan Trailing Blade 25-30o Gravure Roll Coating Pan Reverse Angle 30o 15 16. Doctor Blade Materials High Carbon Spring Steel Stainless Steel Mylar UHMW Different Shapes Most Common = Simple Bevel 17. Pneumatically Loaded On/Off Control Angle Adjustment Coarse: Trailing and Reverse Fine: Attack Angle Oscillation Motor Driven Typical Blade Holder 17 18. Impression Roll Supports Substrate Rubber Covered Roll 65-90 Shore A Durometer Nip Footprint Impression: 0.25 0.375 Controls Coating Width Undercut Roll Lift Edges Off Gravure Roll Unique Roll for Each Web Width Web Gravure Roll Impression Roll 18 19. Impression Roll Impact on Coating Quantity and Quality Roll Durometer Impacts Amount of Coating Transferred Thick Soft Covering (60-70 duro) = Large Footprint = More Coating Thin Hard Covering (80-90 duro) = Small Footprint = Less Coating Higher Precision Leads to Better Coating Uniformity Soft Roll = .002 - .004 TIR Hard Roll = .0005 - .001 TIR Thin Precision Coating Hard Cover Small Footprint Precision Roll 20. Impression Control Pressure Only Pressure in Loading Cylinders Set Impression No Position Stops Between Rolls Difficult to Control Cylinders Lift Roll / Pan / Motor AND Sets Impression Pressure Changes Impact Impression Adjustable Stops Cylinders are Utilized for Positioning Stop Setting Dictates Impression High Loading Pressure = Stability Fine / Repeatable Adjustment Stop Configurations Coarse Thread Differential Screw Taper Wedge Block 20 21. Improvements Enclosed Applicator Sleeve System Cartridge Systems 21 22. Enclosed Applicator Supply Impression / Back-up Roll Coated Web Incoming Web Return Enclosed System No Slinging of Coating Minimizes Solvent Evaporation Reduced System Volume High Rate of Recirculation Minimizes Air Entrapment Foam Control Flows Out of Chamber Easy to Clean Simple Flushing Systems Minimize Waste Gravure Roll 22 23. Enclosed Applicator 23 24. Impression Roll: Sleeve System Impression Roll: Rubber Covered Sleeve Steel Mandrel Drive Side Cantilever Support Operator Side Removable Bearing Support Quick Width Change 5 Minute Task 24 25. Impression Roll: Sleeve System Air Pressure Expands Sleeve Floats Off Mandrel Straight or Tapered Mandrel Sleeves Nickel Composite 25 26. Cartridge System Base Frame and Drive Stand Fixed in Web Line Gravure Roll, Impression Roll and Coating Applicator on Cartridge Quick Change System Off-Line Clean-up Coating Change 10 Minute Change-out Time Typical Features Precision Rails Maintain Alignment Quick Connects for Air and Electrical Tool-less Quick Disconnect Drive Coupling 26 27. Cartridge System Base Frame with Applicator Roll, Impression Roll and Drive Stand Fixed in Web Line Gravure Cartridge Installed Five Motors on Drive Stand 5-Roll Transfer Coating Two Rolls on Base Three Rolls on Cartridge Quick Change System Switch Between Methods Clean-up Off-Line 10 Minute Change-out Time 27 28. Variations Reverse Gravure Offset Gravure Differential Offset Gravure Pressurized Applicator Two-Side Coating 28 29. Reverse Gravure Reverse Application Speed Range: 90-120% Benefits Removes Cell Pattern Film Split Avoided Minimizes Ribbing Adjust Coat Weight with Roll Speed Impression Control is Critical Light / Controlled Impression Precision Required Better Rolls Driven Impression Roll Suggested for Tension Control Overcome Reverse Action Impression / Back-up Roll Gravure Roll Doctor Blade Coating Pan Coated Web Incoming Web 29 30. Offset Gravure 3-Roll System Gravure is Offset from Substrate Removes Substrate from Coating Nip Protects Sensitive Substrates Roll Rotation All Roll Same Direction Synchronous Rotation Two Film Splits Thinner Coatings Roll Speeds All Rolls at 100% Line Speed Single Drive is Possible Gravure Roll is Typically Driven Idle Mode Applicator Roll is Nip Driven Back-up Roll is Web Driven Steel Back-up Roll Gravure Forward Doctor Blade Coating Pan Coated Web Incoming Web Rubber Applicator Roll Forward Film Split 30 Film Split 31. Differential Offset Gravure 3-Roll System Roll Rotation Gravure: Forward / Reverse Applicator: Forward / Reverse Roll Speeds Gravure: Variable Applicator: Variable Back-Up: Controls Tension All Rolls are Driven Roll Function Gravure: Coat Weight Control Applicator: Appearance Control Doctor Blade 31 Steel Back-up Roll Gravure Fwd / Rev Coating Pan Coated Web Incoming Web Rubber Applicator Roll Fwd / Rev Film Split Film Split 32. Differential Offset Gravure Cartridge Coater All Driven Rolls Additional Drives for 5- Roll Coating Wide Range of Set-ups Gloss Top Coat Gravure = 100%, Applicator = 100% Silicone Coating Gravure = 5%, Applicator = 95% 32 33. Process Handles: 2-Roll Gravure Coat Weight and Appearance Direct Gravure - Forward Application 1. Gravure Roll Selection 2. Gravure / Back-up Roll Nip Footprint Direct Gravure Reverse Application 1. Gravure Roll Selection 2. Gravure / Back-up Roll Nip Footprint 3. Gravure Roll Direction 4. Gravure Roll Speed 33 34. Process Handles: 3-Roll Gravure Coat Weight and Appearance Offset Gravure 1. Gravure Roll Selection 2. Gravure / Applicator Roll Nip Footprint 3. Applicator / Back-up Roll Nip Footprint Differential Offset Gravure 1. Gravure Roll Selection 2. Gravure / Back-up Roll Nip Footprint 3. Applicator / Back-up Roll Nip Footprint 4. Gravure Roll Direction 5. Gravure Roll Speed 6. Applicator Roll Direction 7. Applicator Roll Speed 34 35. Pressurized Coating Applicator Pressurized Applicator Tri-Helical Gravure Roll 35 36. Pressurized Coating Applicator Conventional Applicator: No Pressure Pressurized Applicator: Low Pressure Pressurized Applicator: Higher Pressure 36 37. Pressurized Coating Applicator Pressurized Applicator Adjustable Coat Weight with a Single Cylinder 50-100% Weight Increase Reduced Gravure Roll Inventory Extended Coat Weight Range Thicker Coatings Constant Coat Weight with Increasing Speed More Efficient in Filling Gravure Cells Less Recirculation and Foam Generation Higher Viscosity and % Solids 37 38. Simultaneous Two-Side Coating Gravure Roll Gravure Roll Very Cost Effective Coat Both Sides at One Coating Station Single Dryer vs. Dual Dryers Reduced Overall Line Length Direct Application (Kiss Coating) Forward or Reverse Apply Coat Weight is Susceptible to Tension Variations Limited Range of Applications Thinner Coatings Same / Similar Functional Coatings on Both Sides 39. Two-Side Coating Offset Kiss Coat Unsupported Applicator Roll Gravure Roll Gravure Roll Applicator Roll Offset Coat Supported Applicator Roll Applicator Roll Gravure Roll Gravure Roll 40. Versatility Application Range Speeds: 0 - 2000+ fpm Widths: 0 - 200+ inches Substrates: Papers Boards Films Foils Wovens / Non-wovens Coating Types: Water Based Solvent Based 100% Solids (UV and E-Beam Cure) Hot Melt: Adhesives and Waxes 40 41. Versatility Viscosity and Wet Coating Thickness: 2-Roll Gravure: 10-1000 cps 0.0005 0.0015 3-Roll Gravure 50 2000 cps 0.0001 0.001 Pressurized Gravure 100 5000 cps 0.0005 0.005 Coatings: PSAs: Solvent, Aqueous and Hot Melt PVDC and other Barrier Coatings Primer Coats Topcoats: High Gloss and Protective Laminating Adhesives Silicones: Solvent, Aqueous, 100% Solids .. 41 42. 42 Top Coats for Wear Resistance on Magazines Gloss / Color Snap Coatings for Automotive Brochures Adhesives for Wood Grain Patterned Coverings on Furniture Gas Emissive Coatings for Medical Packaging Protective Coatings on Appliance Overlay Optically Clear Adhesives for Protective Window Films Silicone Based Release Liners for Medical Bandages Pressure Sensitive Adhesives for Medical Bandages Versatility Lamination Adhesives for Medical Drapery Primer Coatings for Aluminum Layer in Cigarette Packaging Optically Clear Adhesives for Bottle Labels Adhesives on Masking Films Reactive Coatings on Thermal Papers Pre-Paste on Wall Coverings Tinting of Decorative Fabrics Laminating Adhesives for Lottery Tickets Bonding Layer for Foam / Fabric Headliners 43. Questions? Thank You! Graphic References Doctor Blades Benton Graphics Gravure Roll Slides: Zecher Pamarco Enclosed Applicator Harris and Bruno 43 John Looser New Era Converting Machinery P.O. Box 377 Hawthorne, NJ 07506 Phone: 973-413-4605 E-mail: john.looser@neweraconverting.comwww.neweraconverting.com