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High-Efficiency Roller Coating Line for Pulp Molding with ≥90% Transfer Efficiency and ±2% Coating Accuracy

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High-Efficiency Roller Coating Line for Pulp Molding with ≥90% Transfer Efficiency and ±2% Coating Accuracy

Price : Negotiation

Roller Diameter : 200-400mm

Delivery Time : 30 Working Days

Controlsystem : PLC with touch screen interface

Coating Type : Roller Coating

Packaging Details : Wood Packaging

Feature : Efficient

Payment Terms : T/T

Coating Width : 800mm

Coatingwidth : Up to 2000 mm

MOQ : 1 Set

Production Cycle : 30 days

Supply Ability : Negotiation

Maxcoatingwidth : 1500 mm

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High-Efficiency Roller Coating Line for Pulp Molding with ≥90% Transfer Efficiency and ±2% Coating Accuracy
This roller coating production line is engineered for applying uniform, high-performance internal barrier coatings—waterproof, oil-proof, and heat-resistant—to molded pulp tableware and packaging products. The precision roller coating process uses a dosing roller and applicator roller system with independently adjustable speeds to evenly spread coating over internal surfaces, eliminating pinholes and ensuring consistent dry film thickness.
Unlike spray coating methods, roller coating delivers transfer efficiency of ≥90-95%, drastically reducing material waste—critical for high-value barrier materials such as bio-based polymers and PFAS-free formulations. The closed-loop roller system minimizes volatile emissions, coating contamination, and workplace mess.
With intelligent PLC control and recipe-driven operation, the equipment supports fully customizable drying profiles, roller speed programs, and product fixture designs to accommodate different product geometries, coating formulations, and production throughputs.
Technical Parameters
Parameter Specification / Range Customization Options
Roller Coating Method Single or double roller coating (dosing + applicator) Customizable: single sided or double sided
Applicator Roller Diameter Φ200 / Φ250 mm Customizable
Dosing Roller Diameter Φ123 / Φ150 mm Customizable
Roller Speed Range 0 - 20 m/min (stepless adjustable via VFD) Customizable speed profiles
Coating Thickness (Wet) Adjustable: 0.01 - 2.0 mm Adjustable via roller gap
Coating Thickness Accuracy ±2% coating weight uniformity Optimized via closed loop control
Production Capacity 10 - 40 cycles/min (≈ 240 - 800+ pcs/hour) Customizable per product configuration
Max Product Size (L×W×H) 400 × 300 × 150 mm (customizable) Customizable fixtures and product nests
Compatible Coating Types Water based dispersions, PE, PLA, bio based barriers, PFAS free solutions Customizable for solvent based (explosion proof enclosure option)
Drying Method Multi zone IR + forced hot air Customizable: IR only, hot air only, UV LED, or NIR
Drying Temperature Range 40 - 150°C (zone independent PID control) Customizable temperature profiles
Power Supply 380V / 400V / 460V, 50/60Hz, 3 phase Configurable to regional standards
Control System PLC with 10-15″ HMI touchscreen, 500 recipe storage Customizable automation protocols
Data Logging USB, Ethernet/IP, Profinet; optional FDA 21 CFR Part 11 Customizable data reporting formats
Overall Line Dimensions (L×W×H) Approx. 8,000 - 15,000 × 2,200 × 2,200 mm Customizable layout and footprint
Materials (Contact Surfaces) SUS304 food grade stainless steel --
Safety Features Light curtain, emergency stops, enclosure interlock, over temperature protection Customizable per factory requirements
Compliance CE, ISO9001 Additional certifications available
Note: All technical parameters are customizable to meet specific production requirements and product specifications.
Applications
  • Food Service Ware: Internal barrier coating for plates, bowls, clamshells, lunch boxes, cup carriers—ensuring water resistant and oil resistant performance with PFAS free coatings
  • Egg Trays & Produce Trays: Moisture barrier coating for fruit and vegetable packaging to extend shelf life
  • Electronics Packaging: Anti-static trays for semiconductors, circuit boards, hard drives—requiring precision coating uniformity
  • Industrial Packaging: Corner protectors, edge guards, pallet supports—durable coating for mechanical protection
  • Medical Device Trays: Sterile barrier packaging with high cleanroom compatibility requirements
  • Cosmetics Packaging: Premium molded fiber inserts and display trays—aesthetic and functional coating
  • Pharmaceutical Blister Pack Inserts: Tablet trays requiring uniform, food grade barrier coating
Materials compatibility: Suitable for various pulp formulations including bamboo pulp, bagasse (sugarcane pulp), and recycled paper pulp, with customizable parameter adjustments for different fiber compositions and product thicknesses.
Customization Options
  • Roller Configuration: Customizable roller diameter (Φ200/Φ250 mm), roller hardness (50-90 Shore A), and number of coating heads (1 or 2)
  • Roller Gap Adjustment: Customizable wet coating thickness from 0.01 to 2.0 mm via precision roller gap setting
  • Product Fixtures (Nests): Customizable dedicated fixtures for each product shape with quick change system; changeover <5 minutes
  • Drying Zone Configuration: Customizable drying profiles—add UV LED, modify IR/hot air ratio, or integrate additional cooling sections
  • Coating Application System: Customizable dosing pump types (peristaltic, precision syringe, diaphragm) for different coating viscosities
  • Control Interface: Customizable automation levels—manual, semi-automatic, or fully automated with MES/ERP integration
  • Line Length and Layout: Customizable line configuration—compact placement for limited space or extended conveyor for large-scale lines
  • Cleanroom Compatibility: Customizable cleanroom integration—ISO 5 to ISO 8 with HEPA/ULPA filtration and positive pressure enclosure
  • Coating Parameters: Customizable pre-set and adjustable programs for different coating materials, viscosities, and application targets
  • System Integration: Customizable I/O interfaces (Ethernet/IP, Profinet, dry contacts) for seamless integration with existing pulp molding presses and factory automation systems
Key Features
  • Precision Roller Coating Technology: Chrome plated dosing roller with rubber applicator roller ensures consistent film thickness (±2% coating weight accuracy) and eliminates pinholes common in spray application
  • High Material Efficiency: Roller coating achieves ≥90-95% material transfer efficiency—significantly higher than air spray (40-60%), reducing coating material costs by 30-50% for high value barrier coatings
  • Independent Roller Speed Control: Dosing and applicator rollers operate with independently adjustable speeds—customizable for different coating viscosities and thickness requirements
  • Recipe Driven Changeover: Store 500+ recipes; change between product families or coating formulations in <5 minutes—ideal for flexible manufacturing
  • Integrated Staged Drying: IR + forced hot air in-line drying eliminates separate curing ovens and double handling, reducing work in process inventory
  • Closed Loop Pressure Control: Ensures consistent coating weight (±2%) and thickness uniformity (>95% across all products)
  • Energy Saving Design: VFD controlled blowers, IR zones that activate only with product presence, and standby power mode reduce energy consumption
  • Tool-Less Fixture Change: Quick release product nests minimize downtime between production runs
  • Food Grade Construction: All product contact surfaces in SUS304 stainless steel ensure compliance with food safety standards
  • Full Data Traceability: Batch logging of coating speed, temperature, and coating weight for quality control compliance and ISO certification audits
  • Heavy Duty Modular Construction: Scalable via bolted sections—expandable for future capacity upgrades
  • Safety & Compliance: Built-in light curtains, emergency stops, enclosure interlocks, and over-temperature protection; ISO9001 certified
Support and Services
  • Installation & Commissioning: On-site setup and calibration by experienced engineers (2-3 weeks on site) with customizable support packages available
  • Comprehensive Training: Hands-on training for operators, maintenance staff, and R&D personnel—5-10 days on-site training included
  • Warranty & Maintenance: 1 year comprehensive warranty on turntable drive, roller motors, PLC, pumps, and all electronics; customizable preventive maintenance contracts available
  • Remote Support: 24/7 remote troubleshooting via video call or IoT monitoring with VPN access to PLC for real-time diagnostics, software updates, and parameter tuning
  • Process Development: Free sample testing and process development—send your molded pulp products; we provide a full optimization report including coating thickness, uniformity, and barrier performance
  • Technical Consultation: Free lifetime technical consultation and future upgrade services for evolving production needs
  • Lifetime Support: Technical assistance via phone, email, or online chat for the lifetime of the equipment
Packing and Shipping
  • Packing: Securely packed in reinforced wooden crates with anti-rust film and waterproof wrapping; sensitive components protected with foam padding
  • Standard Lead Time: 30 - 45 working days after order confirmation for standard configurations
  • Custom Lead Time: Customizable delivery schedules—50-70 days for fully customized lines
  • Shipping: Worldwide shipping via sea freight, air freight, or rail; FOB / CIF terms available
  • Documentation: Full export documentation including technical manuals, electrical schematics, CE declaration, and customs forms provided
  • Customizable Options: Export crating, custom labeling, destination port documentation, and special handling instructions available upon request
Frequently Asked Questions
Q1: What is the typical production capacity of this roller coating line?
Production capacity ranges from 240-800+ pieces per hour depending on configuration (10-40 cycles/minute, product dependent). By adding stations or increasing conveyor speed, throughput can exceed 1,000 pieces per hour. Capacity is fully customizable based on your target production volume and product geometry.
Q2: What types of coatings are compatible with the roller coating process?
The line is compatible with water-based dispersions (PE, PLA, bio-based polymers), PFAS-free barrier coatings, oil-proof emulsions, and functional additives (anti-static, hydrophobic). For solvent-based coatings, we can upgrade the enclosure with explosion-proof electricals and enhanced exhaust—a customizable option.
Q3: How does roller coating compare to spray coating in terms of material waste and coverage uniformity?
Roller coating achieves transfer efficiency ≥90-95% (material applied vs. material used)—significantly higher than air spray (40-60%). The precision roller system spreads coating uniformly across internal surfaces, eliminating pinholes and streaks common in spray application. For high-value barrier coatings (e.g., bio-based polymers), roller coating can reduce material costs by 30-50%.

Product Tags:

High-Efficiency Roller Coating Line

      

≥90% Transfer Efficiency Roller Coating Equipment

      

±2% Coating Accuracy Pulp Molding Coating Machine

      
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