Specializing in custom design and problem-solving capabilities, Sun Process offers custom converting services to make your decorative and functional components in the exact shape and size you need.
Sun Process Converting is a full service coater and converter specializing in pressure sensitive materials. We work with a broad range of industry clients to develop custom decorative and functional materials, including marketing materials, industrial foils, paper backed tapes, print-treated polyester, and a number of other flexible plastics.
Working out of our 200,000-square foot, ISO 9001:2015 certified facility, we draw on a number of core manufacturing techniques to create and convert materials:
- Coating and laminating
- Die cutting
- Sheeting and flat cutting
- Hot stamping
Between these processes and our selection of coatings, laminates, and stock materials, we create attractive and functional materials for virtually any application.
Coating and Laminating
Coating and laminating are performed on a coating line. The process is complex and materials undergo multiple coating and laminating processes including: liner release coating; adhesive coating/drying/curing; optional facestock topcoating or primer coating, and lamination of the facestock or carrier to a liner.
Sun Process Converting offers roll-to-roll and roll-to-sheet lamination, as well as a full range of coating services, such as:
- Adhesive coating
- Barrier coating
- Top coating
- One-sided coating
- Two-sided coating
- In-line corona treatment
- Pressure sensitive coating
- Contract coating
We also offer pilot coating to help clients with adhesive formulations or product prototyping.
Our laminating and coating services are fully customizable and comply with relevant industry standards, regulations, and environmental guidelines, so you can be sure that your solution is a perfect fit for your project and your industry.
Die cutting is used to precisely cut a material into a desired shape. Depending on the project, a manufacturer may use either a standard or a custom die, which serves as the template for the die cut product. Once crafted, the tooling can be used to replicate a shape thousands of times with virtually no variation.
We can perform rotary die cutting, steel rule die cutting, thermal die cutting, or punch pressing on most materials, including:
We carry a range of stock materials and we also custom coat or convert customer supplied materials for die cutting applications.
Sun Process’s die cutting capabilities are extensive; as specialists in adhesive backed materials, we are especially adept at cutting through multi-layered materials. Our expert depth calibration and state-of-the-art equipment allow us to tackle die cutting challenges that our competitors cannot achieve.
The slitting process is central to material converting as it allows manufacturers to slit a large roll of material into multiple smaller rolls. The goal of slitting is to produce rolls that are narrow enough to run through standard industrial equipment. Slitting allows manufacturers to use almost any client requested material in their laminating, coating, or cutting processes, even when that material is only available in non-standard sizes.
Sun Process Converting consistently achieves excellent tolerances on materials such as:
- Adhesive tapes
- Industrial foil
We perform score, shear, rotary, razor, single-knife, and zero-tension precision slitting on materials up to 80” in width and 0.050” in material thickness. Within these material constraints, our precision slitting equipment can accommodate even large rolls up to 40” in diameter. These capabilities are key to our ability to offer a full range of material choices to our diverse industry clients.
Sheeting and Flat Cutting
Sheeting and flat cutting are similar processes used to cut a material into precise sheet sizes with exact corners and consistent dimensions. Our sheeting and flat cutting processes allow us to deliver uniform sheets ranging from 1” x 1” to 60” x 120” when sheeting, or 1” x 1” to 85” x 85” when flat cutting. This service is especially important if you use automated sheet fed equipment, as even small size variations can cause jams or loading errors in these scenarios.
Hot stamping is a printing technique that uses heat, pressure, and metallic or colored foils to impress a printed image onto a sheet of material. Hot stamping is cost effective and versatile; capable of printing by the roll or by the sheet, even for non-standard shapes. As such, hot stamping is an excellent complement to die cutting, efficiently adding visual interest to mass-produced products. In fact, our top-of-the-line equipment can simultaneously hot stamp, overlaminate, and die cut, maximizing efficiency without sacrificing quality.
Sun Process Converting uses dry transfer inks to hot stamp clean images up to 5.875” x 7.875” in size. We print in one to three colors, including metallics, using digital tracking technology for precise placement.
Trust Sun Process Converting for Coating, Laminating, Slitting, and Sheeting
Sun Process Converting has been a custom coater and converter for almost 50 years, specializing in pressure sensitive decorative and functional materials. We offer an extensive range of coating, laminating, and cutting services designed to achieve the exact results you need. Our clients have access to a broad catalog of stock materials and tooling, but we also offer completely custom services, and customers have the option of sending in their own material for conversion and coating. In either case, we pride ourselves on delivering high-quality, cost-effective products on time and to exact specifications.
To learn more about how our coating, lamination, and cutting services work together ,contact Sun Process today.