development center pilot coater

Development Center

To support the development of specialized and proprietary coating applications, Dürr Megtec has an in-house Development Center featuring a roll-to-roll pilot coater with flotation drying capabilities. The pilot line includes coating and drying capabilities, providing a fully controlled test environment for complete process development and testing for short production runs.

Located in our De Pere, Wisconsin, USA, facility, the in-house pilot coating and drying line offers mixing capabilities for the preparation of slurry mixtures, multiple coating methods, a three-zone dryer that can be used with a wide range of substrates and tensions, plasma and corona treater for foil substrates, and on-line coating thickness measurement and tracking.

The Dürr Megtec pilot coating line can help you conduct proprietary research and development, and test and optimize new or existing coatings, web materials and processes. The pilot coater facilities help avoid unnecessary expenditures of overhead, capital equipment and start-up costs while developing new products. It also provides the versatility and confidentiality needed for new product development, as well as the ability to produce prototype materials for further research, marketing, and quality testing.

Process engineers, R&D technicians, and analytic staff leverage their collective expertise to solve drying and coating challenges for an ever-increasing array of substrates.

Benchtop process tools

In-house drying lab: A bench-top system that captures complete drying characteristics of coated substrates from small-size samples. The system enables our process engineers to track rates of evaporation for water and organic solvents, along with determining the drying time required to reach target solvent or moisture residuals in the product. The drying lab is geared toward the early scale-up steps in formulation development, drying characterization, optimization and troubleshooting.

Heat transfer stand: Used for thermal characterization of drying and curing nozzles over a wide range of application conditions. Capabilities include quantitative heat transfer coefficient characterization and qualitative analysis of drying conditions to prevent defects, among other capabilities.

Parallel plate rheometer: Used to characterize the rheology of coating fluids to set up slot dies for optimal performance during coating trials.

Hirox® Digital 3D microscope: Used for measuring coated samples, quality, defect analysis, and visual characterization of 3D objects/samples (catalyst, media, etc.).