April 26th, 2018

Extrusion Coating

 

Versatile and Efficient Extrusion Coating

Davis-Standard’s extrusion coating and laminating expertise is second to none. With the industry’s most versatile equipment platforms, we deliver cost-effective extrusion coating packages to support construction, consumer products and packaging industries.

Our extrusion coating machinery fulfills even the most demanding flexible packaging, non-wovens, paper and board coating and laminating applications. This includes everything from laboratory-size systems for R&D to five-meter-wide systems for industrial materials.

We’re innovators in automatic profile control (APC), deckle and die options, multi-coating solutions, web handling, transfer unwinds and winders. Quality, efficiency and value enable us to improve coating and laminating processes for customers worldwide.

Flexible Packaging

Our extrusion coating solutions for flexible packaging offer the best and most innovative technology available. We also engineer our systems to be cost-effective and efficient. Equipment advantages include shafted or shaftless unwinds and winders, material handling, single and double direction turrets with automatic splicing and transfer systems. We also offer the latest screw designs and control technology to support your process. Our liquid coating product line augments these capabilities by supplying the latest in priming and drying so that the highest levels of adhesion can be achieved. In addition, liquid coating and laminating equipment for adhesive or dry-bond lamination could be added to the extrusion coating and laminating line to further expand its capabilities. We have relationships with the major vendors of corona discharge equipment worldwide, giving us the ability to seamlessly integrate their treaters into our flexible packaging extrusion coating and laminating lines.

Typical Specifications

Applications - Lidding stock, candy wrappers, snack food bags, medical packaging, condiment packs, soup sachets, toothpaste tubes, cable wrap, lamination, films
Widths - 500 to 2000 mm / 20 to 80 inches
Line Speeds - 100 to 750 mpm / 300 to 2500 fpm
Tension Range - 35 to 350 n/m / 0.2 to 2.0 pli
Thickness Range - 12 to 100 gsm / 0.5 to 4 mils
Finished Roll Diameter - Up to 1250 mm / Up to 50 inches
Extruder Output - Up to 1000 kg single extruder, up to 1850 kg co-extrusion arrangement (three extruders) / Up to (2200 lbs single extruder, up to 4000 lbs co-extrusion arrangement (three extruders)
Features - Wide range of line equipment solutions to suit customer's requirements and budgets, latest controls systems, full lines and systematic upgrade/retrofits

Paper Coating & Laminating

Davis-Standard’s extrusion coating technology for paper coating and laminating is widely used throughout the industry. Our systems support the ability of our customers to produce quality products as efficiently as possible. Advantages of our technology include shaftless turret unwind and winder designs, superior screw designs and control technology. To augment these capabilities, our liquid coating group supplies the latest in adhesion enhancing priming, logo printing and web drying. We also have relationships with major global vendors of corona discharge equipment and flame treaters with the ability to seamlessly integrate their units into our extrusion coating and laminating lines. For high-speed lines, ozone can be introduced immediately into the lamination nip.

Typical Applications

Applications - Sugar pouch, roll wrap, ream wrap, header stock, insulation facing, cement bags
Widths - 1500 to 3000 mm] / 60 to 120 inches
Line Speeds - 300 to 610 mpm / 1000 to 2000 fpm
Web Thickness Range - 10 to 150 gsm / 6 to 100 lbs / 3000 ft2
Finished Roll Diameter - Up to 1800 mm, depending on core size Up to 72 inches, depending on core size
Extruder Output - Up to 1000 kg single extruder, up to 1850 kg in co-extrusion arrangement (three extruders) Up to 2200 lbs single extruder, up to 4000 lbs in co-extrusion arrangement (three extruders)
Features - Wide range of line equipment solutions to suit customer's requirements and budgets, latest controls systems, full lines and systematic upgrade/retrofits

Board Coating & Laminating

Davis-Standard’s extrusion coating technology is the gold standard in the board coating business as proven by a long and successful track record of installations worldwide. Our unwind and winder sections are shaftless turret designs. Winders are supplied in the single drum horizontal rail style. For loading and unloading large paper rolls, we can easily integrate existing material handling processes. We also offer superior control systems and feedscrew designs. To augment these capabilities, our liquid coating product line includes the latest in adhesion enhancing priming, logo printing and web drying. We have relationships with all of the major vendors of flame treaters, making it possible to seamlessly integrate their units into our board extrusion coating and laminating lines. For high-speed lines, ozone can be introduced immediately into the lamination nip. For applications where foil or film substrates are laminated to the board, high-speed foil unwinds are capable of splicing 5 to 9 micron (0.002-0.0035 inches) to maintain process speed.

Typical Specifications


Applications - Aseptic packaging, paper cup and plate stock, decorative boxes, cigarette boxes, milk and juice cartons, ovenable boards, beer carriers, pet food boxes
Widths - 1200 to 3500 mm / 48 to 140 inches
Line Speeds - 300 to 650 mpm / 1000 to 2150 fpm
Tension Range - 175 to 1750 n/m / 1 to 10 pli
Finished Roll Diameter - Up to 3000 mm depending on core size 120 inches, depending on core size
Extruder Output - Up to 1000 kg single extruder, up to 2750 kg in co-extrusion arrangement (three extruders) Up to 200 lbs single extruder, up to 6000 lbs in co-extrusion arrangement (three extruders)
Features - Wide range of line equipment solutions to suit customer's requirements and budgets, latest controls systems, full lines and systematic upgrade/retrofits

Fabric Scrim & Non-Wovens

We supply specialty equipment designed to handle the required substrates using mono or coextrusion coating with unique pre-heating, winding and unwinding equipment. These components are application specific to meet process needs. Various slitting systems for edge and in-line slitting are also available.

Typical Specifications

Line Sizes - 2 to 4 meters wide / 80 to 160 inches wide
Gear-In Speeds - 150, 300 and 450 mpm / 500, 1000 and 1500 fpm
Typical Products - Sacks, bags, tarps, gowns, diapers, breathable laminates

Aseptic Packaging

Davis-Standard is the global market leader in Aseptic packing film, providing best-in-class solutions for quick changes, waste reduction and precision web handling. We tailor systems to address diverse structures, regulatory and business needs. And it’s all backed by regional after-sale support and service.

Specifications

  • Triplex extrusion coating and laminating line for paper, aluminum foils and/or film
  • Surface treatment on both sides of the board
  • Machine line speed - 350, 450, 600, or 800 m/min
  • Maximum web width - 1350, 1650, 1900 mm
  • Maximum roll diameter for paper - 1600 up to 2000 mm
  • Shaftless unwind and winder
  • Web tension range depending on substrate and width
PPF Film

Paint protection film (PPF) is a growing market segment. This thermoplastic urethane (TPU) base “self-healing” film is ideal for protecting surfaces in automotive, aerospace and electronic applications. TPU films are formulated to provide advantages such as abrasion resistance, impact resistance, puncture resistance, hardness, optical clarity, thermal protection and more.

A typical PPF structure, consisting of a 2-mil release liner, mounting adhesive, TPU film, self-healing coating and 2-mil protective film, is manufactured in a two-pass operation. Davis-Standard is equipped to supply an entire PPF system including the extrusion and solution coating lines. The line consists of components such as extruder, controls, turret winder/roll changer, turret unwind, web cleaner, cartridge coater, roll support dryer, and laminator designed per customer requirements. Davis-Standard also offers equipment audits and consultation for a customer’s existing machine set-up to determine what is needed to process a wider range of materials. Laboratory trials determine the quality of new structures, outputs, process parameters, and the feasibility of adding PPF capabilities.

Typical Specifications

Applications – Surface protection, industrial specialties, consumer electronics, transportation
Widths – 62 to 74 inches (1,575 to 1,880mm)
Thickness – 5 to 12 mils
Materials – TPU

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