Solutions to high-speed film coating

The operating speeds of high-speed film coaters will soon reach 1500mpm and 8gsm/side in a production environment. They will have the ability to apply both low solids starch and high solids coating solution with minimal changes to mechanical equipment. Non-uniform film coating application has historically been one of the limiting factors towards attaining these operating speeds. The issues associated with film coating such as non-uniform film application and misting can be resolved by addressing the following areas: mechanical equipment design, coating formulations and basesheet properties. Pilot trial work was conducted to study and evaluate these variables and their effect on paper and print properties. Results given in this paper are only preliminary. Further development work is planned to further improve the coating quality achievable with a film coater.