Production Level Modular Coating Line (MCL)

The Modular Coating Line (MCL) is available in 300mm and 600mm configurations and serves a variety of end-use applications. A wide range of coatings including solvent, aqueous, E-Beam and UV may be processed on the MCL with the available standard options offered.

Flexible Design Allows for Custom Configuration & Expansion

Modular Coating Line MCL
The modular design utilizes pre-engineered components. A complete line, even with the amount of customization available, can be delivered quickly at a lower cost than an equivalent machine produced from completely customized drawings, without sacrificing quality.

Flexibility of the configuration makes the MCL highly adaptable to fit the needs of all markets.

The drive can be preselected for either low-speed or high-speed web processing. Drives and controls are completely integrated, and installation costs are minimized by prewiring and piping to the greatest extent possible. Ductwork is provided to connect the heating and air-handling skids to the dryer in the predefined location.

Interchangeable Coating Modules Offer Flexibility for All Markets

Coating modules are interchangeable so the MCL can be configured for a variety of coating methods that satisfy a broad range of applications. Coating modules can be added at any time as needs change. The MCL′s modular construction with integral drive and control cabinets for each component makes future reconfiguration easier and reduces field installation time and expense.

A Flex Spreader Roll is included prior to the coater to reduce web-handling problems associated with baggy edges or centers of the web.
Modular Coating Line MCL Modules

Winding

The MCL includes one rewind and two unwinds: primary and laminate.

A Cantilevered Single Roll can be unwound/wound in either direction. Closed-loop control with tension readout ensures regulated, constant winding tension. Roller bearings are located along the shaft and the adapter to facilitate roll removal. Winders include a regenerative drive, cantilevered air shaft, and full-length adapter.

The Roll Cart supports 610 mm (24″) diameter rolls up to 227 Kg (500 lbs.) with 635 mm (25″) maximum core lengths.

Static Elimination is effected by two single-sided, non-contact ionizing devices located at the primary unwind and rewind.

Winding Options

options checkboxWeb guide
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Foil handling package
options checkboxPlasma coated rollers for self-wound PSA
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Turret with automatic splicer and transfer units
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Dual fixed position spindles
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Lay-on roll for single roll rewind

Lamingating & Chilling

The Dry-Bond Laminator includes a double wall chrome plated laminating roll which can be heated, and dual post lamination chill rolls. The nip with adjustable stops can achieve a maximum loading of 150 PLI (26 N/mm). A fully enclosed guard protects operators from moving parts, while removable panels allow access for maintenance.

Optional Wet-Bond Laminator Module easily attaches to 3-Roll Coater Module for quick-change laminating configurations.

Flex Spreader Rolls are provided for both incoming webs.

Laminating Options

options checkboxRotary unions and hoses
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Hot water unit
options checkboxHot oil unit
options checkboxChiller
options checkboxWeb bond laminator

Drying & Curing

The Single-Zone, High-Efficiency Gas Heated Flotation Dryer has a double-wall enclosure. The dryer box is constructed of aluminized steel with internal headers, includes upper impingement nozzles, lower airfoils (for web stability) and freestanding air-handling units. The three-meter dryer section has access doors with double pane web observation windows to allow easy access for web-up and cleaning.

The Dryer Exit Guide includes electro mechanical actuator, ultrasonic sensing head and guide roll.

Drying & Curing Options

options checkboxAdditional dryer zones available in 3-meter sections
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Electric heat in lieu of gas burners
options checkboxHEPA filters
options checkboxBelt or Idler support
options checkboxCounter flow
options checkboxDryer recirculation with manual mockdown
options checkboxLEL monitor for solvent-based coatings
options checkboxStainless steel dryer interior
options checkboxCooling zone with flotation top and bottom air
options checkboxUV cure unit configured for single or double row non-inert operation or single row nitrogen inert operation
options checkboxE-beam curing

Control Systems

Control Systems are designed and integrated by Faustel and include a Main Operator Console, Local Operator Stations, a Sectional Drive System and Programmable Logic Controller with open source code.

Contact Faustel for a complete description of the new Modular Coating Line at 262-253-3333.

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