At Sun Process Converting Inc., we offer our customers contract coating and lamination services, providing customized solutions to enhance product quality and cost effectiveness.
Sun Process Converting is a leader in custom coating and laminating. We offer a broad range of products and services to fulfill each customer’s unique application. We offer solvent, emulsion, and UV permanent and removable pressure sensitive adhesives. We also work with heat sensitive adhesives and offer a variety of release liners for custom coating.
Our processes include in-line corona treatment, remoistening, top coating, barrier coating and pilot coating for experiments and formula adjustments. Committed to product quality and cost-effectiveness, our highly experienced and knowledgeable team designs and implements the coating and laminating solutions specific to each customer’s needs.
At Sun Process, each one of these processes undergo strict quality assurance testing consistent with industry standards and regulations, and environmental guidelines.
Coating and Laminating Capabilities
As a leader in coating and laminating services, Sun Process offers a variety of products and applications. Our extensive range of coating and laminating processes include the following services: adhesive coating, roll-to-roll laminating, roll-to-sheet laminating, top coating, barrier coating, and contract coating.
Adhesive coating is the method of applying adhesives onto films, plastics, and papers to give the substrate bonding ability to various surfaces. Depending on the needs of the application, adhesive coatings can be manufactured for pressure or heat activation. Pressure-sensitive adhesives will adhere to the material’s surface after applying pressure, while heat sensitive adhesives require the application of heat in order to activate its adherent properties.
In the roll-to-roll laminating process, pressure rollers work to apply the adhesive film to a substrate. Then, pressure rollers work to apply this film to a surface, such as a paper or card. The resulting laminate coating covers both sides of the material, thereby strengthening the product and protecting it from external damage. Roll-to-roll laminating offers the capability of protecting or embellishing a printed document or image.
Roll-to-sheet lamination is the process of applying roller pressure as the laminating film and substrate come together to be joined.
Our top coating services are used to increase surface energy and improve adhesion for printability on a variety of products.
Our barrier coating services are used to provide material protection from environmental factors such as heat and moisture.
Sometimes a product requires specialized coatings. Depending on the material and the purpose of the end-product, not having these custom coatings risks performance issues and malfunctions. Rather than expend the time and labor to meet these distinct coating requirements by completing this process in-house, many manufacturers depend on professional coating and laminating services for reliable specialty coatings.
Our Coating Methods
At Sun Process, our state-of-the-art equipment ensures that we can provide all coating and laminating services to meet your application. We carry out processes such as reverse roll coating, direct and reverse gravure coating, and Meyer rod coating. Each process uses different principles of operation, thereby producing different effects in the coating and laminating to meet and exceed your expectations.
Reverse roll coating consists of two or three reverse-rolling nips used to apply liquid coatings to the surface of the material. A partially immersed roller pulls the adhesive from a trough or pan. As the material is held by another nip or roll, and the reverse roll mechanism brings the two rolls into contact via rotation, thereby applying the adhesive coating to the base material. While unnecessary, a third roll serves as a back-up roll, especially for flexible, thin substrates.
Direct and Reverse Gravure
Direct and gravure coating uses ceramic or steel engraved rolls, or gravures, to apply a coating pattern to the product material. Using partial submersion in a pan of the coating or with a mechanism which encloses the coating against the roll, the coating is applied to the gravure. The gravure then rolls to apply the coating in the desired pattern. In the reverse gravure process, similar tools perform the same tasks, except that the reverse gravure method uses three rolls to propel the material and adhesive, as in reverse roll coating.
Meyer rod coating remains one of the most popular coating methods in the industry. A Meyer rod, or a stainless steel rod encased in tightly wound stainless steel wire, allows for added control over the amount of coating applied to the material. It allows for quick and easy thickness changeovers across a broad range of substrates.
Coating and Laminating Solutions by Sun Process Converting
Sun Process provides the ideal solutions for all coating and laminating needs. Our ISO 9001:2015 certified facility includes a state-of-the-art research and development lab, where our products endure rigorous testing and analysis throughout the production process. Completing all of our coating and laminating services in-house, we ensure superior product quality throughout the entire manufacturing process. To learn more about our customizable coating and laminating solutions, contact us today.
Coating & Laminating Specifications:
- Adhesive Coating
- Laminating (Roll to Roll)
- Laminating (Roll to Sheet)
- Top Coating & Barrier Coating
- Contract Coating
- Reverse Roll
- Direct and Reverse Gravure
- Meyer Rod
- One Sided
- Two Sided
- Pressure Sensitive
- Top Coating
- Maximum Roll Width: 62″
- Minimum Material Thickness: .5 mil (.0005″)
- Maximum Material Thickness: 30 mil (.030″)
- Minimum Coating Thickness: .1 mil (.00001″)
- Maximum Coating Thickness: 5 mil (.005″)
- Maximum Roll Diameter: 40″
- Core Diameters: 3″, 6″, 7.5″, 10″
- Maximum Roll Weight: 1,200 lbs.
- Industrial Aluminum Foil
- Home Furnishing
AS – Aerospace Industry Standard
ASME – American Society of Mechanical Engineers
ASTM – American Society for Testing and Materials
CSA – Canadian Standards Association
DOT – Department of Transportation
FAA – Federal Aviation Administration
FDA – Food And Drug Administration
ISO 9001:2008 – International Organization for Standardization
Mil-Spec Military Specifications
NADCAP – National Aerospace And Defense Contractors Accreditation Program
QS – QS Is a quality standard developed by the Automotive Industries
RoHS – Restriction Of Hazardous Substances (Compliant)
SAE -Society of Automotive Engineers
TS – Technical Specifications, used with ISO