Having the right pilot coating system in place speeds product development, aids decision making and is useful for determining overall performance of substrate and coatings over time. The reel-to-reel VCML pilot coater designed and developed by RK is available in web widths of up to 300mm and can accommodate a wide range of flexible substrates and coating technologies.
It is becoming widely used for the development, evaluation, trialling and small-scale production of more sustainable packaging materials and coatings. Most recently, a custom configured VCML was supplied to FPInnovations in Canada, where it is being used by CelluForce to evaluate bio-based barrier coatings incorporating cellulose nanocrystals (CNCs).
Critical chemistry
Chemistry is critical when developing bio-based alternative materials to conventional multilayer plastic packaging, but collaboration is equally important. FPInnovations, a non-profit R & D organisation, works with CelluForce in Montreal to advance the use of CNC formulations for improving various aspects of packaging. One example is CelluShield; a water-based, bio-based barrier coating developed for flexible plastic packaging applications and designed to improve oxygen barrier performance in recycled mono-material packaging structures. When properly applied, this coating forms a dense, uniform barrier layer that can help reduce gas permeation and contribute to extended shelf life.
The VCML pilot coater supplied incorporates direct and offset gravure coating, knife-over-roll and meter bar coating applicator technology. Reverse gravure has also been added. The system is also capable of undertaking wet and dry lamination.
Controlled drying profile
To facilitate the drying of low solids, water-based coatings, the VCML coater is equipped with three hot air impingement drying zones that provide a controlled drying profile across the web.
The VCMLs drying range also supports low solids water-based coatings on a variety of substrates, including porous papers.