Lee A.

Ostness
Product Manager
Coating & Drying Systems
Davis-Standard, LLC

Today with the trend to increase production speeds above 1000 fpm, there is a
need to improve the coating application methods. Primer applications for the
extrusion coating process consisted of Direct Forward Gravure, Direct Reverse
Gravure, Offset Gravure and Smooth Roll Transfer coaters. At the higher
speeds, the ability to apply low coat weights by the existing coaters has become
greatly limited. To produce the desired results at the increased operating speeds,
new coater variations must be employed. The primary goal is to determine the
operating parameters and required modifications for each type of coater to
achieve low coat weights above 1000 fpm.
Yesterdays conventional coaters applying higher coat weights at lower operating
speeds were accepted. Today the price competition is driving the market to
lower the operating cost. This requires the manufacturer to increase speed and
lower coat weights to sustain their position in the market.
Two issues;
1) How do you lower the coat weight?
2) What effects does raising the speed create?
Lowering coat weight can be achieved by updating the coating equipment with
new state of the art technology. Gravure coaters have progressed with the
addition of new pumps, better engraving technology, enclosed applicators, and
pressurized applicators. Other factors include correct plumbing, locating the
applicator in the correct position, rubber Shore A and rubber compound.
The gravure coater consists of a steel roll with a
pattern engraved into the surface, an applicator
doctoring system and a rubber backup roll. The
Offset Gravure coater consists of the same with
the addition of a chrome backup roll and the
rubber roll becomes the transfer roll. The
gravure roll is constructed from a steel shell and
roll journals. Advances to the gravure roll
technology consist of new roll design that can be cooled by filling the center with
cooling water, it can be constructed with a double shell to improve cooling

uniformity, or it can be constructed with spiral flutes to achieve 3 T across

the roll face. The construction of the roll tolerances has improved to produce a
straight roll with consistent TIR. To achieve a more consistent release of the
coating from the gravure pattern, first build up the surface with copper and then
engrave the pattern into the copper then flash chrome plate. This will give a very
uniform pattern verses engraving the steel surface. Another option would be to
coat the surface with a ceramic buildup and laser engrave the pattern into the
ceramic coating. This will lengthen the life of the gravure roll more than 3X. The
ceramic gravures could be a little too course for priming some sensitive films,
foils, or printed surfaces.
The rubber roll has improved with new rubber compounds, more consistent
hardness cross web, and better mechanical durability. The sleeve system has
provided quicker changeover between web width changes and allows the
converter to change rubber compound hardness for multiple product runs. Make
sure you order the correct rubber compound for your application. Smooth Roll
priming the rubber should repel the solution coating while in offset gravure
coating the rubber should wet out the entire surface evenly. For Direct Gravure
coating the rubber does not see the solution coating but should be selected to
with stand friction, heat, swelling and the web surface contaminates.
The applicators for gravure coating have gone from
an open pan with a wiping doctor system to an
enclosed plowing doctoring system. The open pan
was fine for water base coatings at low speeds. With
high line speeds the roll would throw the coating out
of the pan, the enclosed applicator contains all the coating. The enclosed
system incorporates the plowing angle for the doctoring system witch will stay in
contact with the gravure surface at all line speeds. The wiping doctor system
could lift off the roll surface due to hydraulic forces from the coating at higher line
speeds.
The enclosed applicators could cause some foaming issues with the primer
solution if the flow rate is too low. The flow of coating through the enclosed
system should be designed for a minimum of 3 times the amount to be applied to
the web. This means if you are applying 1 gpm to the web you should be
supplying 3 gpm to the applicator with 2 gpm recirculated back to the supply
tank. The plumbing of the return lines should be done to cause the least amount
of resistance. Each return line should be independent of the others using the
largest diameter and shortest run as possible avoiding dips which will cause a
plug flow. The atmospheric enclosed applicator should be set up at either
3oclock or 9 oclock positions. The side of the roll will depend
on roll direction. The top doctor blade should be the doctoring
blade to allow smooth flow patterns inside the head. If the
bottom blade is used for doctoring it could cause turbulent flow = foam.

The Direct Forward and Reverse Gravure coaters are ok for 1000 to 1500 fpm
But above the 1000 fpm either a offset gravure coater should be used or an
pressurized applicator be installed. The speed of the gravure roll will increase
the amount of turbulence in the applicator so the slower the roll speed the better
the application. With Offset Gravure the gravure roll is typically operated
between 25 to 30% of the web speed.
The pressurized gravure head is designed to apply coating to the gravure roll at
high speeds and to reduce the amount of foaming of the primer solution. The
Density Density
preferred design will have small flow channels,
GPM
In
Out
recirculation, and the ability to pressurize. If designed
0.63
9.2
7.77
0.99
8.92
8.3
correctly the density of the solution coating will be the
1.44
8.91
8.5
same after it exits the applicator as it is when it entered.
1.98
8.95
8.63
2.44
8.65
8.64
This is very important tool for primers that foam very easily.
The Smooth Roll coaters operate on the hydraulic force principle. By
determining the correct operating conditions, nip, speed, shore
hardness of the coater the coat weight can be controlled. But at
higher operating speed the hydraulic forces increase so harder
rubber compounds are necessary. The need to crown the rubber
rolls may also be required due to excessive hydraulic
deflection. With higher line speeds the roll speed
increases requiring the coating pan will need to be designed for
higher flow rates and coating slinging. Sling guards are required for
control of the coating being slung from the end of the coating rolls.
For line speeds above 1000 fpm a three roll smooth coater should
be used to reduce the speed of the rolls in the coating pan.
The coating supply pumps should be selected for the correct application. For an
open pan system, a diaphragm pump may be used only if the pan is designed
correctly to eliminate the pulse created by the diaphragm
pump. The centrifugal pump may be used for the open pan
systems and for the enclosed applicators. They must be
sized large enough to allow the correct flow rate taking into
consideration the distance from the coater head and the height up to the coater
head. For higher flow rates and for the pressurized systems a positive
displacement and low shear should be selected.

To lower the coat weight applied and increase line speed for the various coater
setups are as follows:
Direct Forward Gravure
Speeds up to 1000 fpm open pan system,
1. choose the correct gravure pattern
2. update your pan design
3. invert the doctor system from wiping to plowing
Speeds 1000 fpm to 1500 fpm
1. choose the correct gravure pattern
2. replace the pan with an enclosed applicator system
3. if enclosed system already exist make sure its on the correct side of the
gravure roll
4. select the correct pump
5. plump the coating supply system correctly
Speeds 1500 fpm and up
1. choose the correct gravure pattern
2. Replace the open pan or enclosed applicator with a pressurized applicator
3. upgrade the pump to handle the pressure requirement
4. replace the coater with Offset Gravure
Direct Reverse Gravure
Speeds up to 1000 fpm open pan system,
1. choose the correct gravure pattern
2. update your pan design
3. invert the doctor system from wiping to plowing
Speeds 1000 fpm to 1500 fpm
1. choose the correct gravure pattern
2. replace the pan with an enclosed applicator system
3. if enclosed system already exist make sure its on the correct side of the
gravure roll
4. select the correct pump
5. plump the coating supply system correctly
Speeds 1500 fpm and up
1. choose the correct gravure pattern
2. Replace the open pan or enclosed applicator with a pressurized applicator
3. upgrade the pump to handle the pressure requirement
4. Replace the coater with Offset Gravure
Offset Gravure
Speeds up to 1000 fpm, open pan system
1. choose the correct gravure pattern
2. update your pan design
3. invert the doctor system from wiping to plowing
4. reduce the speed of the gravure roll to 20 30% of line speed

Speeds 1000 fpm to 1500 fpm

1. choose the correct gravure pattern
2. replace the pan with an enclosed applicator system
3. if enclosed system already exist make sure its on the correct side of the
gravure roll
4. select the correct pump
5. plump the coating supply system correctly
6. reduce the speed of the gravure roll to 20 30% of line speed
Speeds 1500 fpm and up
1. choose the correct gravure pattern
2. Replace the open pan or enclosed applicator with a pressurized applicator
3. upgrade the pump to handle the pressure requirement
4. Replace the coater with Offset Gravure
5. reduce the speed of the gravure roll to 20 30% of line speed

Smooth Roll (2 Roll System)

Speeds up to 1000 fpm
1. use the correct pressure setting
2. determine the correct roll speed
3. update the rubber roll
4. update your pan design
5. upgrade the sling guard
Speeds from 1000 fpm to 1500 fpm
1. use the correct pressure setting
2. determine the correct roll speed
3. increase the rubber hardness from 60 to 80 Shore A
4. update your pan design
5. upgrade the sling guard
Speeds from 1500 fpm and up
1. replace the 2 roll system with the 3 roll system
2. use the correct pressure setting
3. determine the correct roll speeds
4. increase the rubber hardness from 60 to 80 Shore A
5. update your pan design
6. upgrade the sling guard
Smooth Roll (3 roll system)
Proprietary set up see me

2007 PLACE
Conference
September 16-20
St Louis, MO

High Speed Priming

How To Lower Coat Weight & Raise Line Speed

Presented by:

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

PRIMER COATERS
DIRECT GRAVURE

REVERSE GRAVURE

OFFSET GRAVURE

SMOOTH ROLL

Methodology of Application

Gravure Coater

Smooth Roll Coater

Gravure Style Coaters

Increase Speed Lower Coat Weight

Gravure pattern
Doctor system
Applicator design
Air entrainment in the Coating
Pump
Plumbing

Gravure Engraved Patterns

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

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
5%
15%
SOLIDS SOLIDS
0.21
0.26
0.23
0.29
0.26
0.32
0.51
0.64
0.56
0.70
0.64
0.80
0.77
0.96
0.81
1.02
0.85
1.06
1.03
1.20
0.98
1.22
1.02
1.28
1.15
1.44
1.28
1.60
1.49
1.86
1.58
1.98
1.94
2.42
2.30
2.88
2.67
3.33

25%
SOLIDS
0.32
0.36
0.40
0.80
0.88
1.00
1.20
1.28
1.32
1.40
1.52
1.60
1.80
2.00
2.32
2.48
3.02
3.60
4.16

35%
SOLIDS
0.47
0.53
0.59
1.18
1.30
1.48
1.78
1.89
1.95
2.07
2.25
2.37
2.66
2.96
3.43
3.67
4.47
5.33
6.15

45%
SOLIDS
0.70
0.79
0.88
1.75
1.92
2.19
2.63
2.80
2.89
3.07
3.33
3.50
3.94
4.38
5.08
5.43
6.61
7.88
9.11

PYRAMID CELL
5%
15%
SOLIDS SOLIDS
0.17
0.21
0.19
0.23
0.20
0.26
0.41
0.51
0.45
0.56
0.51
0.64
0.61
0.77
0.65
0.82
0.68
0.85
0.82
0.96
0.78
0.98
0.82
1.02
0.92
1.15
1.02
1.28
1.19
1.49
1.26
1.58
1.55
1.94
1.84
2.30
2.13
2.66

25%
SOLIDS
0.26
0.29
0.32
0.64
0.70
0.80
0.96
1.02
1.06
1.12
1.22
1.28
1.44
1.60
1.86
1.98
2.42
2.88
3.33

35%
SOLIDS
0.38
0.42
0.47
0.94
1.04
1.18
1.42
1.51
1.56
1.66
1.80
1.90
2.13
2.37
2.74
2.94
3.58
4.26
4.92

45%
SOLIDS
0.56
0.63
0.70
1.40
1.54
1.75
2.10
2.24
2.31
2.46
2.66
2.80
3.15
3.50
4.06
4.34
5.29
6.30
7.29

DIRECT REVERSE GRAVURE

CHART #8
PYRAMID CELL
CELL
15%
5%
VOLUME
DEPTH
SOLIDS SOLIDS
0.0008
2.6
0.14
0.17
0.0009
3.2
0.15
0.19
0.0010
3.4
0.16
0.20
0.0020
7.5
0.33
0.41
0.0022
8.2
0.36
0.45
0.0025
9.7
0.41
0.51
0.0030
11.0
0.49
0.61
0.0032
11.9
0.52
0.65
0.0033
12.2
0.54
0.68
0.0035
13.9
0.66
0.77
0.0038
16.0
0.63
0.78
0.0040
17.3
0.66
0.82
0.0045
18.0
0.74
0.92
0.0050
20.4
0.82
1.02
0.0058
24.4
0.95
1.19
0.0062
26.6
1.01
1.27
0.0076
33.7
1.24
1.55
0.0090
41.0
1.47
1.84
0.0104
48.0
1.71
2.13

25%
SOLIDS
0.20
0.23
0.26
0.51
0.56
0.64
0.77
0.82
0.84
0.90
0.97
1.02
1.15
1.28
1.48
1.59
1.93
2.30
2.66

35%
SOLIDS
0.30
0.34
0.38
0.76
0.83
0.95
1.14
1.21
1.25
1.32
1.44
1.52
1.70
1.89
2.20
2.35
2.86
3.41
3.94

OFFSET GRAVURE
CHART #12
PYRAMID CELL
CELL
5%
15%
VOLUME
DEPTH
SOLIDS SOLIDS
0.0008
2.6
0.06
0.07
0.0009
3.2
0.06
0.08
0.0010
3.4
0.07
0.08
0.0020
7.5
0.14
0.17
0.0022
8.2
0.15
0.18
0.0025
9.7
0.17
0.21
0.0030
11.0
0.20
0.25
0.0032
11.9
0.21
0.27
0.0033
12.2
0.22
0.28
0.0035
13.9
0.27
0.32
0.0038
16.0
0.26
0.32
0.0040
17.3
0.27
0.34
0.0045
18.0
0.30
0.38
0.0050
20.4
0.34
0.42
0.0058
24.4
0.39
0.49
0.0062
26.6
0.42
0.52
0.0076
33.7
0.51
0.64
0.0090
41.0
0.61
0.76
0.0104
48.0
0.70
0.88

25%
SOLIDS
0.08
0.10
0.11
0.21
0.23
0.26
0.32
0.34
0.35
0.37
0.40
0.42
0.48
0.53
0.61
0.65
0.80
0.95
1.10

35%
SOLIDS
0.12
0.14
0.16
0.31
0.34
0.39
0.47
0.50
0.51
0.55
0.59
0.63
0.70
0.78
0.91
0.97
1.18
1.41
1.62

NUMBER
200
180
165
150
142
132
120
116
108
100
90
80
70
65
60
55
50
45
40

CELL
DEPTH
0.0008
0.0009
0.0010
0.0020
0.0022
0.0025
0.0030
0.0032
0.0033
0.0035
0.0038
0.0040
0.0045
0.0050
0.0058
0.0062
0.0076
0.0090
0.0104

VOLUME
2.6
3.2
3.4
7.5
8.2
9.7
11.0
11.9
12.2
13.9
16.0
17.3
18.0
20.4
24.4
26.6
33.7
41.0
48.0

DIRECT FORWARD GRAVURE

CHART #4
CELL
VOLUME
DEPTH
0.0008
0.0009
0.0010
0.0020
0.0022
0.0025
0.0030
0.0032
0.0033
0.0035
0.0038
0.0040
0.0045
0.0050
0.0058
0.0062
0.0076
0.0090
0.0104

2.6
3.2
3.4
7.5
8.2
9.7
11.0
11.9
12.2
13.9
16.0
17.3
18.0
20.4
24.4
26.6
33.7
41.0
48.0

CHART #2

QUADRANGULAR CELL
15%
25%
5%
SOLIDS SOLIDS SOLIDS
0.22
0.32
0.48
0.27
0.40
0.60
0.33
0.48
0.72
0.30
0.49
0.80
0.46
0.68
1.00
0.51
0.76
1.12
0.55
0.81
1.20
0.59
0.87
1.28
0.71
1.05
1.56
0.80
1.19
1.76
0.90
1.32
1.96
0.98
1.46
2.16
1.10
1.62
2.40
1.19
1.76
2.60
1.24
1.84
2.72
1.28
1.89
2.80
1.64
2.43
3.60
2.19
3.25
4.80
3.11
4.60
6.80

35%
SOLIDS
0.71
0.89
1.07
1.30
1.48
1.66
1.78
1.89
2.31
2.61
2.90
3.20
3.55
3.85
4.03
4.14
5.33
7.10
10.06

QUADRANGULAR CELL
5%
15%
25%
SOLIDS SOLIDS SOLIDS
0.18
0.26
0.38
0.22
0.32
0.48
0.26
0.39
0.58
0.24
0.39
0.64
0.37
0.54
0.80
0.41
0.60
0.90
0.44
0.65
0.96
0.47
0.69
1.02
0.57
0.84
1.25
0.64
0.95
1.41
0.72
1.06
1.57
0.79
1.17
1.73
0.88
1.30
1.92
0.95
1.40
2.08
0.99
1.47
2.18
1.02
1.51
2.24
1.31
1.95
2.88
1.76
2.60
3.84
2.49
3.68
5.44

35%
SOLIDS
0.57
0.71
0.86
1.04
1.18
1.33
1.42
1.51
1.85
2.09
2.32
2.56
2.84
3.08
3.22
3.31
4.26
5.68
8.05

45%
SOLIDS
0.45
0.51
0.56
1.12
1.23
1.40
1.68
1.79
1.85
1.96
2.13
2.24
2.52
2.80
3.25
3.48
4.23
5.04
5.83

DIRECT REVERSE GRAVURE

CHART #9
QUADRANGULAR CELL
CELL
15%
25%
5%
VOLUME
DEPTH
SOLIDS SOLIDS SOLIDS
0.0012
5.7
0.14
0.21
0.31
0.0015
7.5
0.17
0.26
0.38
0.0018
9.4
0.21
0.31
0.46
0.0022
10.9
0.19
0.32
0.51
0.0025
13.3
0.29
0.43
0.64
0.0028
15.0
0.33
0.48
0.72
0.0030
16.0
0.35
0.52
0.77
0.0032
17.2
0.38
0.55
0.82
0.0039
21.4
0.46
0.67
1.00
0.0044
26.3
0.51
0.76
1.13
0.0049
30.0
0.57
0.85
1.25
0.0054
32.0
0.63
0.93
1.38
0.0060
35.4
0.70
1.04
1.54
0.0065
40.4
0.76
1.12
1.66
0.0068
44.5
0.79
1.17
1.74
0.0070
46.6
0.82
1.21
1.79
0.0090
58.7
1.05
1.56
2.30
0.0120
81.0
1.40
2.08
3.07
0.0170
117.0
1.99
2.94
4.35

35%
SOLIDS
0.45
0.57
0.68
0.83
0.95
1.06
1.14
1.21
1.48
1.67
1.86
2.05
2.27
2.46
2.58
2.65
3.41
4.54
6.44

45%
SOLIDS
0.18
0.21
0.23
0.46
0.51
0.58
0.69
0.74
0.76
0.81
0.88
0.92
1.04
1.16
1.34
1.43
1.75
2.08
2.41

OFFSET GRAVURE
CHART #13
QUADRANGULAR CELL
CELL
5%
15%
25%
VOLUME
DEPTH
SOLIDS SOLIDS SOLIDS
0.0012
5.7
0.06
0.09
0.13
0.0015
7.5
0.07
0.11
0.16
0.0018
9.4
0.09
0.13
0.19
0.0022
10.9
0.08
0.13
0.21
0.0025
13.3
0.12
0.18
0.26
0.0028
15.0
0.13
0.20
0.30
0.0030
16.0
0.14
0.21
0.32
0.0032
17.2
0.15
0.23
0.34
0.0039
21.4
0.19
0.28
0.41
0.0044
26.3
0.21
0.31
0.46
0.0049
30.0
0.24
0.35
0.52
0.0054
32.0
0.26
0.38
0.57
0.0060
35.4
0.29
0.43
0.63
0.0065
40.4
0.31
0.46
0.69
0.0068
44.5
0.33
0.48
0.72
0.0070
46.6
0.34
0.50
0.74
0.0090
58.7
0.43
0.64
0.95
0.0120
81.0
0.58
0.86
1.27
0.0170
117.0
0.82
1.21
1.80

35%
SOLIDS
0.19
0.23
0.28
0.34
0.39
0.44
0.47
0.50
0.61
0.69
0.77
0.84
0.94
1.02
1.06
1.09
1.41
1.87
2.66

NUMBER
200
190
180
165
150
140
130
120
110
96
85
75
65
55
45
35
30
25
16

CELL
DEPTH
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

VOLUME
5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

DIRECT FORWARD GRAVURE

CHART #5
CELL
VOLUME
DEPTH
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

CHART #3

CELL
DEPTH
0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

45%
SOLIDS
1.05
1.31
1.58
1.93
2.19
2.45
2.63
2.80
3.42
3.85
4.29
4.73
5.26
5.69
5.96
6.13
7.88
10.51
14.89

50%
SOLIDS
1.31
1.63
1.96
2.39
2.72
3.05
3.26
3.48
4.24
4.79
5.33
5.88
6.53
7.07
7.40
7.62
9.79
13.06
16.50

45%
SOLIDS
0.84
1.05
1.26
1.54
1.75
1.96
2.10
2.24
2.74
3.08
3.43
3.78
4.21
4.55
4.77
4.90
6.30
8.41
11.91

50%
SOLIDS
1.05
1.30
1.57
1.91
2.18
2.44
2.61
2.78
3.39
3.83
4.26
4.70
5.22
5.66
5.92
6.10
7.83
10.45
13.20

45%
SOLIDS
0.67
0.84
1.01
1.24
1.40
1.57
1.68
1.79
2.19
2.46
2.75
3.03
3.37
3.64
3.81
3.92
5.04
6.73
9.53

50%
SOLIDS
0.84
1.04
1.25
1.53
1.74
1.95
2.09
2.23
2.71
3.07
3.41
3.76
4.18
4.52
4.74
4.88
6.27
8.36
10.56

45%
SOLIDS
0.28
0.35
0.42
0.51
0.58
0.65
0.69
0.74
0.90
1.02
1.13
1.25
1.39
1.50
1.57
1.62
2.08
2.77
3.93

50%
SOLIDS
0.35
0.43
0.52
0.63
0.72
0.81
0.86
0.92
1.12
1.26
1.41
1.55
1.72
1.87
1.95
2.01
2.58
3.45
4.36

NUMBER CELL DEPTH

120
110
95
90
84
79
72
64
59
54
50
45
42
36
35
33
28
26
24

0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140

VOLUME
18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0

TRI-HELICAL CELL
5%
15%
25%
SOLIDS
SOLIDS
SOLIDS
0.64
0.95
1.40
0.73
1.08
1.60
0.94
1.39
2.05
1.03
1.52
2.25
1.14
1.69
2.50
1.18
1.75
2.58
1.32
1.95
2.88
1.50
2.22
3.28
1.61
2.39
3.53
1.76
2.60
3.85
1.91
2.83
4.18
2.14
3.17
4.68
2.19
3.25
4.80
2.64
3.91
5.78
2.80
4.09
5.98
2.81
4.16
6.15
3.22
4.77
7.05
3.81
5.63
8.33
4.09
6.05
8.95

QUADRANGULAR CELL
5%
15%
25%
VOLUME
SOLIDS SOLIDS SOLIDS
5.7
0.22
0.32
0.48
7.5
0.27
0.40
0.60
9.4
0.33
0.48
0.72
10.9
0.30
0.49
0.80
13.3
0.46
0.68
1.00
15.0
0.51
0.76
1.12
16.0
0.55
0.81
1.20
17.2
0.59
0.87
1.28
21.4
0.71
1.05
1.56
26.3
0.80
1.19
1.76
30.0
0.90
1.32
1.96
32.0
0.98
1.46
2.16
35.4
1.10
1.62
2.40
40.4
1.19
1.76
2.60
44.5
1.24
1.84
2.72
46.6
1.28
1.89
2.80
58.7
1.64
2.43
3.60
81.0
2.19
3.25
4.80
117.0
3.11
4.60
6.80
DIRECT FORWARD GRAVURE
CHART #6

QUADRANGULAR CHANNELED CELL

5%
15%
25%
35%
SOLIDS
SOLIDS
SOLIDS
SOLIDS
0.20
0.30
0.44
0.65
0.25
0.37
0.55
0.82
0.30
0.45
0.66
0.98
0.28
0.45
0.74
1.20
0.42
0.62
0.92
1.36
0.47
0.70
1.03
1.53
0.50
0.74
1.10
1.64
0.54
0.80
1.18
1.74
0.65
0.97
1.44
2.13
0.74
1.09
1.62
2.40
0.82
1.22
1.80
2.67
0.91
1.34
1.99
2.94
1.01
1.49
2.21
3.27
1.09
1.62
2.39
3.54
1.14
1.69
2.50
3.71
1.18
1.74
2.58
3.81
1.51
2.24
3.31
4.90
2.02
2.99
4.42
6.53
2.86
4.23
6.26
9.26

CELL DEPTH

VOLUME

0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

DIRECT REVERSE GRAVURE

CHART #10

QUADRANGULAR CHANNELED CELL

5%
15%
25%
35%
SOLIDS
SOLIDS
SOLIDS
SOLIDS
0.16
0.24
0.35
0.52
0.20
0.30
0.44
0.66
0.24
0.36
0.53
0.79
0.22
0.36
0.59
0.96
0.34
0.50
0.74
1.09
0.38
0.56
0.82
1.22
0.40
0.60
0.88
1.31
0.43
0.64
0.94
1.39
0.52
0.78
1.15
1.70
0.59
0.87
1.30
1.92
0.66
0.97
1.44
2.13
0.72
1.07
1.59
2.36
0.81
1.19
1.77
2.61
0.87
1.29
1.91
2.83
0.91
1.35
2.00
2.97
0.94
1.39
2.06
3.05
1.21
1.79
2.65
3.92
1.61
2.39
3.53
5.23
2.29
3.38
5.00
7.40

CELL DEPTH

VOLUME

0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

OFFSET GRAVURE
CHART #14

35%
SOLIDS
2.07
2.37
3.03
3.33
3.70
3.81
4.26
4.85
5.22
5.70
6.18
6.92
7.10
8.55
8.74
9.10
10.43
12.32
13.24

QUADRANGULAR CHANNELED CELL

5%
15%
25%
35%
SOLIDS
SOLIDS
SOLIDS
SOLIDS
0.07
0.10
0.15
0.22
0.08
0.12
0.18
0.27
0.10
0.15
0.22
0.32
0.09
0.15
0.24
0.39
0.14
0.21
0.30
0.45
0.15
0.23
0.34
0.50
0.17
0.25
0.36
0.54
0.18
0.26
0.39
0.57
0.22
0.32
0.47
0.70
0.24
0.36
0.53
0.79
0.27
0.40
0.60
0.88
0.30
0.44
0.66
0.97
0.33
0.49
0.73
1.08
0.36
0.53
0.79
1.17
0.38
0.56
0.83
1.22
0.39
0.57
0.85
1.26
0.50
0.74
1.09
1.62
0.67
0.99
1.46
2.16
0.94
1.40
2.06
3.05

CELL DEPTH

VOLUME

0.0012
0.0015
0.0018
0.0022
0.0025
0.0028
0.0030
0.0032
0.0039
0.0044
0.0049
0.0054
0.0060
0.0065
0.0068
0.0070
0.0090
0.0120
0.0170

5.7
7.5
9.4
10.9
13.3
15.0
16.0
17.2
21.4
26.3
30.0
32.0
35.4
40.4
44.5
46.6
58.7
81.0
117.0

45%
SOLIDS
3.07
3.51
4.49
4.93
5.48
5.64
6.30
7.18
7.73
8.44
9.15
10.25
10.52
12.66
13.10
13.48
15.45
18.25
19.62

50%
SOLIDS
3.80
4.35
5.57
6.11
6.79
6.99
7.81
8.89
9.57
10.46
11.34
12.70
13.04
15.68
16.23
16.70
19.15
22.61
24.31

45%
SOLIDS
0.97
1.21
1.45
1.78
2.01
2.25
2.42
2.58
3.15
3.54
3.95
4.35
4.84
5.23
5.48
5.64
7.25
9.67
13.70

50%
SOLIDS
1.21
1.50
1.80
2.20
2.50
2.81
3.00
3.20
3.90
4.41
4.90
5.41
6.01
6.50
6.81
7.01
9.01
12.02
15.18

45%
SOLIDS
0.77
0.96
1.16
1.42
1.61
1.80
1.94
2.06
2.52
2.83
3.16
3.48
3.87
4.19
4.39
4.51
5.80
7.74
10.96

50%
SOLIDS
0.96
1.20
1.44
1.76
2.00
2.24
2.40
2.56
3.12
3.53
3.92
4.33
4.81
5.20
5.45
5.61
7.21
9.61
12.14

45%
SOLIDS
0.32
0.40
0.48
0.59
0.66
0.74
0.80
0.85
1.04
1.17
1.30
1.44
1.60
1.73
1.81
1.86
2.39
3.19
4.52

50%
SOLIDS
0.40
0.49
0.60
0.73
0.83
0.93
0.99
1.06
1.29
1.45
1.62
1.79
1.98
2.15
2.25
2.31
2.97
3.97
5.01

35%
SOLIDS
0.71
0.89
1.07
1.30
1.48
1.66
1.78
1.89
2.31
2.61
2.90
3.20
3.55
3.85
4.03
4.14
5.33
7.10
10.06

CHARTS REFERENCED FROM:

PAMARCO, INC.
ARC INDUSTRIES, INC.
AMERICAN ENGRAVING AND MACHINE CO.
MODERN ENGRAVING AND MACHINE CO.

NOTE: THIS IS FOR CHROME PLATED GRAVURE ROLLS ONLY !

1. DETERMINE SOLIDS
2. DETERMINE TYPE OF GRAVURE COATER
3. DETERMINE TYPE OF GRAVURE CELL
4. FIND THE DESIRED COATWEIGHT IN THE CHART

45%
SOLIDS
1.05
1.31
1.58
1.93
2.19
2.45
2.63
2.80
3.42
3.85
4.29
4.73
5.26
5.69
5.96
6.13
7.88
10.51
14.89

50%
SOLIDS
1.31
1.63
1.96
2.39
2.72
3.05
3.26
3.48
4.24
4.79
5.33
5.88
6.53
7.07
7.40
7.62
9.79
13.06
16.50

5. TRACE THAT ROLL OVER TO THE VOLUME IN THE SAME CHART

6. CHOOSE THE ROLL FROM ANY VENDOR CHART THAT
MATCHES THE VOLUME AND CELL TYPE.

DIRECT FORWARD GRAVURE

CHART #7
CELL DEPTH

VOLUME

0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140

18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0

DIRECT REVERSE GRAVURE

CHART #11
CELL DEPTH

VOLUME

0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140

18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0

OFFSET GRAVURE
CHART #15
CELL DEPTH

VOLUME

0.0022
0.0025
0.0032
0.0035
0.0039
0.0040
0.0045
0.0051
0.0055
0.0060
0.0065
0.0073
0.0075
0.0090
0.0093
0.0096
0.0110
0.0130
0.0140

18.0
20.3
26.2
28.8
32.3
32.7
36.8
41.8
45.0
49.0
53.3
59.6
61.5
73.3
76.0
78.2
90.0
106.5
115.0

TRI-HELICAL CELL
5%
15%
25%
SOLIDS
SOLIDS SOLIDS
0.51
0.76
1.12
0.58
0.86
1.28
0.75
1.11
1.64
0.82
1.22
1.80
0.91
1.35
2.00
0.95
1.40
2.06
1.05
1.56
2.30
1.20
1.77
2.62
1.29
1.91
2.82
1.41
2.08
3.08
1.53
2.26
3.34
1.71
2.53
3.74
1.76
2.60
3.84
2.11
3.13
4.62
2.24
3.27
4.78
2.25
3.33
4.92
2.58
3.81
5.64
3.05
4.51
6.66
3.27
4.84
7.16

35%
SOLIDS
1.66
1.90
2.42
2.66
2.96
3.05
3.41
3.88
4.18
4.56
4.94
5.54
5.68
6.84
6.99
7.28
8.34
9.86
10.59

45%
SOLID
2.46
2.81
3.59
3.94
4.38
4.51
5.04
5.74
6.18
6.75
7.32
8.20
8.42
10.13
10.48
10.78
12.36
14.60
15.70

TRI-HELICAL CELL
5%
15%
25%
SOLIDS
SOLIDS SOLIDS
0.41
0.61
0.90
0.47
0.69
1.02
0.60
0.89
1.31
0.66
0.97
1.44
0.73
1.08
1.60
0.76
1.12
1.65
0.84
1.25
1.84
0.96
1.42
2.10
1.03
1.53
2.26
1.12
1.66
2.46
1.22
1.81
2.68
1.37
2.03
3.00
1.40
2.08
3.07
1.69
2.50
3.70
1.79
2.62
3.83
1.80
2.66
3.94
2.06
3.05
4.51
2.44
3.60
5.33
2.62
3.87
5.73

35%
SOLIDS
1.32
1.52
1.94
2.13
2.37
2.44
2.73
3.10
3.34
3.65
3.96
4.43
4.54
5.47
5.59
5.82
6.68
7.88
8.47

45%
SOLID
1.96
2.25
2.87
3.16
3.51
3.61
4.03
4.60
4.95
5.40
5.86
6.56
6.73
8.10
8.38
8.63
9.89
11.68
12.56

TRI-HELICAL CELL
5%
15%
25%
SOLIDS
SOLIDS SOLIDS
0.17
0.25
0.37
0.19
0.29
0.42
0.25
0.37
0.54
0.27
0.40
0.59
0.30
0.45
0.66
0.31
0.46
0.68
0.35
0.51
0.76
0.40
0.59
0.87
0.43
0.63
0.93
0.46
0.69
1.02
0.50
0.75
1.10
0.57
0.84
1.24
0.58
0.86
1.27
0.70
1.03
1.53
0.74
1.08
1.58
0.74
1.10
1.62
0.85
1.26
1.86
1.01
1.49
2.20
1.08
1.60
2.36

35%
SOLIDS
0.55
0.63
0.80
0.88
0.98
1.01
1.12
1.28
1.38
1.50
1.63
1.83
1.87
2.26
2.31
2.40
2.75
3.25
3.50

45%
SOLID
0.81
0.93
1.19
1.30
1.45
1.49
1.66
1.90
2.04
2.23
2.42
2.71
2.78
3.34
3.46
3.56
4.08
4.82
5.18

Gravure Applicator Design

Wiping vs. Plowing

Open Pan

vs.

Location of Enclosed Applicator

Enclosed

vs.

Pressurized

Pressurized Gravure Applicator

zThe

ability to pressurize the PGH limits the effect of dwell and

ensures that the gravure cells will be filled with the coating. A
standard enclosed applicator is restricted by the time the
gravure cell is in the wetted chamber. Thusly, with the PGH the
gravure cells will be filled at higher speeds than with a
standard applicator or open pan system.

GPM
0.63
0.99
1.44
1.98
2.44

Density
In
9.2
8.92
8.91
8.95
8.65

Density
Out
7.77
8.3
8.5
8.63
8.64

OFFSET GRAVURE
Gravure Pattern
Rubber compound
Gravure Speed
Enclosed Applicator

Smooth Roll Coaters

Increase Speed Lower Coat Weight

Pan design
Splashing
Slinging
Rubber compound
Rubber hardness

SMOOTH ROLL

Rubber Hardness/Compound

Multi Chamber Pan

Sling Guards

EPDM

HYPOLON

NATURAL
RUBBER

NEOPRENE

SBR

SILICONE

THIOKOL

VITON

G-E

G-E

G-E

Hardness Range

20-100

30-75

25-90

45-85

30-100

10-95

30-100

35-90

15-80

65-80

50-95

10-95

65-95

250

350

350

300

212

250

250

400+

212

500+

275

212

212

Ozone Resistance

F-G

Cut Resistance

F-G

G-E+

F-E

Tear Strength

P-G

F-E

F-G

F-VG G-VG+

Abrasion Resistance

G-E

G-E

F-G

P-F

G-E+

G-E

Heat Resistance

F-G

G-E

G-E

F-G

F-G

G-E

G-E

F-G

P-E

F-G

P-F

P-F

G-E

G-E

F-G

Compression Set

Swell Resistance to
ASTM Oil #1
Swell Resistance to
ASTM Oil #3
Reference for Fuel B
Ketones:
MEK
Aromatics:
Toluene
Aliphatics:
Hexane
Esters:
Ethyl Acetate

Smooth Roll Coater

POLYETHER
URETHANE

BUTYL

Tensile Strength

Max Service
Temperature

Gravure Coater

ARCOTHAN
E
(O SERIES)
POLYESTER
URETHANE

BUNA N

Rubber Rolls

Compound

P-F

P-F

P-F

Cellosolve

P-F

P-F

Chlorinated Solvents:
Methylene Chloride

Trichloroethylene

G-E

G-E

G-E

G-E

G-E

G-E

G-E

G-E

G-E

F-E

F-E

F-E

F-E

F-G

G-E

P-G

P-G

G-E

Glycols:
Diethylene Glycol
Alcohols:
Isopropal Alcohol
Water:
Distelled (75 F)
Caustics:
10%NaOH
Acids:
10% H2SO4
Animal / Vegetable Oils

Correct Pump Selection

Double Diaphragm
Peristaltic
Centrifugal
Positive Displacement

Diaphragm

Peristaltic
Up to 4.5 gpm

Centrifugal

Positive Displacement

Plumbing
Hose Diameter
Drooping return lines
Return Lines Td together
Trough system
Amount of return flow
Pump size
Pump design

Conclusion - Review
Gravure Coaters

Smooth Roll Coaters

Select correct gravure pattern

Pan design
Enclosed Applicator or PGH
Correct Pump
Correct Plumbing
Upgrade to Offset Gravure

Pressure Setting
Roll Speed
Pan Design
Sling Guards
Rubber Hardness
Upgrade to 3-Roll Design

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...