Non-contact flotation dryer

Roll-to-Roll Process Applications

Dürr Megtec continues to pioneer the engineering and development of non-contact flotation dryers and ovens. Its 50+ years of experience, more than 100 patents, and thousands of dryer installations worldwide confirm its leadership position as a world-class supplier of roll-to-roll drying and curing systems for industrial applications.

Customized Industrial Dryers and Ovens for Roll-to-Roll Process Applications

In the industrial sector, drying and curing technologies from Dürr Megtec have been deployed in roll-to-roll processing applications for lithium-ion battery electrode coating, coatings of various types, composites, solar films, membranes, flexible packaging, coil coating, converting, printing, electronics, nonwovens, and other industries.

Our patented flotation air bar systems transport webs contact-free without web shift, which helps ensure product quality. Capable of handling webs at a wide range of speeds and widths, Dürr Megtec flotation dryers float and dry webs of substrates ranging from the thinnest film, foil, paper, and other flexible and advanced materials, to heavy metal.

In the web offset and digital printing markets, Dürr Megtec is synonymous with the development of patented roll-to-roll curing and drying solutions and the integration of dryers and oxidation systems. The result is optimum printing performance, minimized energy and waste costs, all while meeting the strictest environmental requirements.

Dürr Megtec dryers can be built in horizontal, vertical, or arched configurations depending on the specific product and space requirements. Each system incorporates energy-saving features, easy threading, and easy maintenance access. Separate web drying and air handling modules accommodate the most basic design to nearly an unlimited number of configurations with regard to web width, zone configurations, and machine layout.

Designs can include different types of heat sources (convection, UV and infrared), zone lengths, web widths, and nozzle configurations, while providing superior drying, curing and web handling.

High-efficiency heat sources and advanced air flow management conserve energy to minimize operating costs. Whether the application operates with gas, thermal oil, steam or electricity, Dürr Megtec has a heating system designed for these requirements.

Broad Capabilities

Our extensive drying and curing experience for roll-to-roll processes, web-forming processes, and conveyor handling of parts and materials, covers a wide range of applications and dryer styles:

  • Flotation
  • Roll-Support
  • Festoon
  • Catenary
  • Belt/Conveyor Supported
  • Through-Air
  • Inert
  • Clean Room
  • Horizontal, Vertical & Arched

Dürr Megtec dryers are engineered to incorporate easy threading and maintenance access. Separate web drying and air handling modules open the basic design to virtually unlimited configurations with regard to web width, zone configurations, and machine layout. We can supply a standard dryer configuration or provide a customized solution for more difficult process conditions. Designs can include different heat sources, zone lengths, substrate widths, and nozzle configurations for convection dryers, UV drying and curing, and infrared dryers.

Energy-Saving Designs

High-efficiency heat sources and advanced airflow management conserve energy to minimize operating costs. Whether the application operates with gas, thermal oil, steam, or electricity, Dürr Megtec has a heating system designed to meet exact operational requirements.

Easy Maintenance

Dürr Megtec dryers and ovens feature a planar retraction system that separates the top and bottom components to provide ample side-to-side access of the dryer for thread-up, cleaning, and internal maintenance. Accessible fans, motors, and heat sources allow for easy adjustment, service, and maintenance. The complete system package is engineered to optimize production and uptime rates.

Thermal Technology

Our experience in advanced thermal technology is far reaching. The knowledge and understanding of balancing the heat transfer with web handling characteristics is critical. It is the control of drying rates that do not disturb the coating combined with the knowledge and experience of web conveyance that puts Dürr Megtec at the leading edge.

Flotation Dryers

Dürr Megtec flotation dryers float and dry substrates ranging from the thinnest film, foil, paper, and other flexible and advanced materials, as well as heavy metal. Patented air bar technology provides effective and efficient non-contact flotation drying without web shift.

Roll-Support Dryers

Dürr Megtec offers drum dryers to meet process needs. One example is a vacuum drum surrounded by impingement nozzles, which not only dries the substrate, but also eliminates curl. Our patented design is tailored to the application.

Roll Support Dryers

Dürr Megtec offers several oven designs incorporating through-air only or hybrid technology utilizing impingement and through-air for heating, drying, and thermal curing. Some materials exhibit sufficient air permeability to benefit from highly effective through-air oven designs. While supported on an air-permeable belt, heated and dried air pass through the product, thus affecting internal heat and mass transfer within the thickness of the material. Uniform air delivery and passage through the material is controlled using patented Dürr Megtec thermal air management systems.

Conveyor Belt Dryers

Belt dryers and ovens provide continuous support to material as it moves through the oven. Examples include non-woven fiber mats, extensible membranes, friable webs, sheeted materials, low-strength tissue and toweling, and many other materials that cannot sustain tension stresses in roll support or flotation ovens. Convection and optional infrared (IR) heating zones efficiently dry and thermally cure in processing conditions engineered to deliver uniform product quality, while achieving maximum throughput.

Impingement Through-Air Dryers

Dürr Megtec offers gas-fired and electric IR configurations to meet the demands of a variety of products and applications. These include systems designed for complete drying, preheating, pre-drying, fusing, curing and profiling. By combining the correct wavelength infrared and optimizing of the control system, precise process conditions can be achieved to maximize product quality in the most efficient manner.

IR and Hybrid Dryers

Dürr Megtec offers gas-fired and electric IR configurations to meet the demands of a variety of products and applications. These include systems designed for complete drying, preheating, pre-drying, fusing, curing and profiling. By combining the correct wavelength infrared and optimizing of the control system, precise process conditions can be achieved to maximize product quality in the most efficient manner.

IR can be applied in roll support or belt conveyor ovens. In addition, it can be uniquely combined with flotation and/or impingement drying systems to enhance the performance of the overall drying or curing process. Our IR ovens can be designed in horizontal, vertical, or arched configurations depending on the specific product and space requirements.

In critical drying applications, concurrent application of both convection plus IR can enhance drying quality and achieve throughput benefits not possible with convection or IR alone.

Dürr Megtec offers a patented combi-flotation and IR air bar dryer, allowing one- or two-sided IR drying, even in horizontal, as well as vertical web paths without the need for shutters or grating to prevent web fires. In non-flotation applications, combi-IR and convection roll support arrangements are available. This configuration features a patented shutter system for use in applications where quick on-off function of the IR is critical, even in medium-long wave IR applications.

Additional capabilities in drying and curing processes include:

  • Engineering, new technology research and product development 
  • Scale-up from R&D/pilot projects to full-scale production
  • Bench-top drying lab for early scale-up steps in formulation development, drying characterization, optimization & troubleshooting
  • Full-scale pilot line for system/process validation & follow-up tests
  • Heat transfer stand for thermal analysis
  • Drying process analysis modeling to predict test results for confirming full-scale production
  • 3D microscope to measure & characterize dried film