As shown in the diagram below, our pilot facility offers everything that you need to assess the suitability of your product for use with energy curable adhesives, coatings, inks and crosslinkable films. Our Pilot Line includes a UV System as well as an EB system, along with a Thermal Dryer for water based formulations and a Corona Treater for substrates that require surface conditioning. It is capable of processing paper, flexible and semi-rigid packaging materials, films and foil laminates, textiles and nonwoven substrates.

 PILOT LINE CAPABILITIES and SPECIFICATIONS

UV CURING:
200-800 WPI, Mercury, Metal Halide and Gallium Lamps. Air Cooled Irradiator with Cold Mirror Reflectors.

EB CURING:
Voltage range from 80 kV to 200 kV with a depth of 150 microns at density of 1g/cc and a dosage range of 1-9 Mrads depending on speed.

PROCESS WIDTH and SPEED:
Up to 18 inches wide on 3" or 6" cores and a maximum processing speed of 200 fpm.

ROLL COATING CAPABILITY & COAT WEIGHTS:
In line direct, offset and reverse gravure with weights from 1-35 gsm and viscosities up to 20,000 cps. Gravure station can be heated up to 100 C.

EXTRUSION COATING:
In line slot die with weights from 20-100 gsm and viscosity up to 20,000 cps. Station can be heated up to 300 F.

MANUAL DRAWDOWNS:
Mayer Rods are available for sheet substrates.

Beyond the in house proof of principle capabilities described above, EB candidates can be tested in a production environment at Faustel. Located in Germantown, Wisconsin near Milwaukee, Faustel is a world class manufacturer of coating lines, unwind and rewind equipment, and other systems for the converting industry. Their facility includes production scale lines that utilize ESI's EB technology.