In 2023 DACKOR both celebrated our 20th Anniversary and the new installation of a high-tech coating line. The coating line was 3 years in the making and is the first wide-format 60" hot coating line in North America. The line features dual melters, two lacquer/UV coating stations, Excimer with nitrogen for super-matte as well as custom embossing line.
FAQs
Can you coat membrane pressable laminate?
Yes, however at this time we can only coat over uncoated PVCs and PETs that are membrane pressable. Since this is a new product, we would need to test your specific material, and ink set, for adhesion of our coating to your material. We have also tested digitally printed materials and had success. However, if you supply us digitally printed rolls we would need to run a test first.
How do I get started?
Step 1: Speak with one of our sales representatives about what you are trying to accomplish with your finished product. Contact us at 407-654-5013.
Step 2: Choose your rolled substrate such as PVC, paper, OPP, PP, PET, or cast vinyl.
Step 3: Give us the specifications of coat weight, emboss, gloss level, quantities, etc.
Step 2: Choose your rolled substrate such as PVC, paper, OPP, PP, PET, or cast vinyl.
Step 3: Give us the specifications of coat weight, emboss, gloss level, quantities, etc.
How do I use this for exterior?
Typically, exterior grade products will be PVC. However, some other materials may be used if in rolled goods. We would coat using an exterior grade coating. Please note that the base film needs to be UV durable as well as any inks used. The final product can create up to 5,000 taber abrasion.
Some product examples are outdoor decking, outdoor awnings, car wraps. soffits, signage, boat floors, flooring, or wall panel systems.
Some product examples are outdoor decking, outdoor awnings, car wraps. soffits, signage, boat floors, flooring, or wall panel systems.
What are the applications?
- Flooring applications such as LVT and other flooring products.
- Membrane pressed steps, tray tables, and tops.
- Profile wrapped parts, 2D, and 1D rolls.
- Digital print coats for custom designs, or for flooring advertisements for retail.
- Exterior decking, marine components, transportation components, awnings, exterior signs, building materials.
- Super matte, anti-fingerprint designs for rolls of paper, PVC, or PET.
- RV tops, RV steps, stair treads, wall applications.
- More durable coatings for car wraps using calendered PVC, or cast vinyls.
- Membrane pressed steps, tray tables, and tops.
- Profile wrapped parts, 2D, and 1D rolls.
- Digital print coats for custom designs, or for flooring advertisements for retail.
- Exterior decking, marine components, transportation components, awnings, exterior signs, building materials.
- Super matte, anti-fingerprint designs for rolls of paper, PVC, or PET.
- RV tops, RV steps, stair treads, wall applications.
- More durable coatings for car wraps using calendered PVC, or cast vinyls.
What ARE the Capabilities
Below are the details of our capabilities:
- Coating to uncoated rolls of PVC films, paper rolls, PP, OPP, PET, and Recycled PET films.
- Paper must be 30 grams or thicker. Films would usually range from 3 mils/.075mm to 12 mils/0.3mm thickness.
- Hot coating in 35 gram per square meter to 80 gsm for non corundum can be achieved for up to 3,000 taber.
- Hot coating for 85 gsm with corundum (aka aluminum oxide) for up to 5,000 taber.
- MOQ is 200 meters, or 219 Yard rolls. Please note that we will loose some meterage in set up. Ideally, we would coat at least 1,000 meters at a time or more as the first roll looses material in set up. The larger the run, the higher the yield.
- Able to coat DACKOR films and competitor film rolls as contract coating.
- Interior and exterior grade. For exterior rolls the base material must also be exterior grade.
- Performance of 3000 to 5000 taber abrasion.
- Running trials for membrane press applications.
- Prints may be rotary, gravure, or digital.
- Minimum rolls of 20", or 508mm wide, Max media of 61.6" or 1565mm wide, 200 meter minimum.
- Current textures of stipple, super-matte, or one woodgrain emboss. Custom emboss rollers are 35K Euro.
- Various gloss levels possible ranging from 2.5 degree up to 80 degree gloss level.
- Coating to uncoated rolls of PVC films, paper rolls, PP, OPP, PET, and Recycled PET films.
- Paper must be 30 grams or thicker. Films would usually range from 3 mils/.075mm to 12 mils/0.3mm thickness.
- Hot coating in 35 gram per square meter to 80 gsm for non corundum can be achieved for up to 3,000 taber.
- Hot coating for 85 gsm with corundum (aka aluminum oxide) for up to 5,000 taber.
- MOQ is 200 meters, or 219 Yard rolls. Please note that we will loose some meterage in set up. Ideally, we would coat at least 1,000 meters at a time or more as the first roll looses material in set up. The larger the run, the higher the yield.
- Able to coat DACKOR films and competitor film rolls as contract coating.
- Interior and exterior grade. For exterior rolls the base material must also be exterior grade.
- Performance of 3000 to 5000 taber abrasion.
- Running trials for membrane press applications.
- Prints may be rotary, gravure, or digital.
- Minimum rolls of 20", or 508mm wide, Max media of 61.6" or 1565mm wide, 200 meter minimum.
- Current textures of stipple, super-matte, or one woodgrain emboss. Custom emboss rollers are 35K Euro.
- Various gloss levels possible ranging from 2.5 degree up to 80 degree gloss level.
What can't We DO with our ROLL CoATING LINE?
We cannot:
- Coat over existing coatings (typically). You'd order your material uncoated. It can coat directly over most inks and top caps
- Coat panels or sheets using this equipment. This machine is roll to roll. We do have a laminator in which we can laminate clear films over panels. However, we cannot laminate clear films over panels with films that are coated.
- Achieve a mirror finish gloss level. We can achieve 2 degrees to 80 degrees gloss level however the gloss will not be a perfect mirror finish. It may suit your project but not a complete mirror finish.
- Coat small rolls. We can only coat 200 meter rolls in production. However, 1,000 meter rolls or larger are ideal. Our limit is 40" diameter rolls.
- Change the color by our coatings. Although technically possible, it may make the appearance milky and we currently are not offering color change on the production line.
- Turn a matte film to gloss if the matte film is already coated.
- Coat over copies of prints. If you scan and copy designs to be identical from proprietary designs we cannot coat over them due to legal infringement. You can create matches where the print structure is slightly different but we encourage original prints.
- Guarantee adhesion to competitors materials. However, we can do prototypes for you to ensure coating adhesion. We can only QC our own prints to ensure the material is lot to lot consistent.
- Do rapid emboss developments. New embossing rollers take 4 to 6 months to fabricate.
- Coat over existing coatings (typically). You'd order your material uncoated. It can coat directly over most inks and top caps
- Coat panels or sheets using this equipment. This machine is roll to roll. We do have a laminator in which we can laminate clear films over panels. However, we cannot laminate clear films over panels with films that are coated.
- Achieve a mirror finish gloss level. We can achieve 2 degrees to 80 degrees gloss level however the gloss will not be a perfect mirror finish. It may suit your project but not a complete mirror finish.
- Coat small rolls. We can only coat 200 meter rolls in production. However, 1,000 meter rolls or larger are ideal. Our limit is 40" diameter rolls.
- Change the color by our coatings. Although technically possible, it may make the appearance milky and we currently are not offering color change on the production line.
- Turn a matte film to gloss if the matte film is already coated.
- Coat over copies of prints. If you scan and copy designs to be identical from proprietary designs we cannot coat over them due to legal infringement. You can create matches where the print structure is slightly different but we encourage original prints.
- Guarantee adhesion to competitors materials. However, we can do prototypes for you to ensure coating adhesion. We can only QC our own prints to ensure the material is lot to lot consistent.
- Do rapid emboss developments. New embossing rollers take 4 to 6 months to fabricate.
HOW DOES THIS LINE WORK?
This is one continuous line over 60' long.
STAGE 1: Hot Coating
Our coating line uses PUR technology in drums which are melted and dispersed over our 60" wide line. The roll goods can be up to 62" and we can slightly coat over 60" such as 60 1/2". For interior it uses either corundum of 15%, 30% or non corundum. The range of non corundum is typically 25 gsm to 60 gsm and the range of corundum is a minimum of 80 gsm to a max of 110 gsm. We currently run 15% corundum. For exterior we run 30% corundum between 90gsm to 110gsm.
STAGE 2: Lacquering stations 1 and 2.
We have two lacquer stations in line with UV curing. If coating 6-8 gsm of lacquer one station would be used. However, if 12 gsm to 16gsm we would use both stations. For example, 6 gsm on station 1 and 6 gsm on station 2 to create a total of 12 gsm. This creates more clarity and performance. Our capability by lacquer is only 5 to 80 degree gloss level.
Please note that we can also coat with lacquer only on papers, PVCs and PETs. However, this would not be embossable.
STAGE 3: Excimer
The optional excimer is utilized when we wish to achieve 2 to 5 degrees gloss level with anti finger print technology. The surface is a superficial polymerisation, which causes a volume shrinkage manifesting itself in surface folds of varying degrees. This deformed "skin" leads to a diffuse reflection of the light, which we perceive as a matt effect. To completely cure the coating layer, it is immediately cured by irradiation with a UV dryer. We utilize an on-site nitrogen supply to reduce oxidation of the lamps. This technology enables us to be a contract coater for rolled goods with high-performance , anti-scratch super matte.
STAGE 4: Embossing
Currently, we have one embossing roller with a woodgrain emboss all over. The embossing goes into the hot coating to create realistic woodgrain textures. New emboss rollers take 4 to 6 months to fabricate and must be ceramic coated in order to endure when we use the line for corundum (aluminum oxide).
STAGE 5: Rewind and Inspection
The final stage is the rewind and inspection of the roll. This is serviced by a full room 2.5 ton gantry crane.
STAGE 1: Hot Coating
Our coating line uses PUR technology in drums which are melted and dispersed over our 60" wide line. The roll goods can be up to 62" and we can slightly coat over 60" such as 60 1/2". For interior it uses either corundum of 15%, 30% or non corundum. The range of non corundum is typically 25 gsm to 60 gsm and the range of corundum is a minimum of 80 gsm to a max of 110 gsm. We currently run 15% corundum. For exterior we run 30% corundum between 90gsm to 110gsm.
STAGE 2: Lacquering stations 1 and 2.
We have two lacquer stations in line with UV curing. If coating 6-8 gsm of lacquer one station would be used. However, if 12 gsm to 16gsm we would use both stations. For example, 6 gsm on station 1 and 6 gsm on station 2 to create a total of 12 gsm. This creates more clarity and performance. Our capability by lacquer is only 5 to 80 degree gloss level.
Please note that we can also coat with lacquer only on papers, PVCs and PETs. However, this would not be embossable.
STAGE 3: Excimer
The optional excimer is utilized when we wish to achieve 2 to 5 degrees gloss level with anti finger print technology. The surface is a superficial polymerisation, which causes a volume shrinkage manifesting itself in surface folds of varying degrees. This deformed "skin" leads to a diffuse reflection of the light, which we perceive as a matt effect. To completely cure the coating layer, it is immediately cured by irradiation with a UV dryer. We utilize an on-site nitrogen supply to reduce oxidation of the lamps. This technology enables us to be a contract coater for rolled goods with high-performance , anti-scratch super matte.
STAGE 4: Embossing
Currently, we have one embossing roller with a woodgrain emboss all over. The embossing goes into the hot coating to create realistic woodgrain textures. New emboss rollers take 4 to 6 months to fabricate and must be ceramic coated in order to endure when we use the line for corundum (aluminum oxide).
STAGE 5: Rewind and Inspection
The final stage is the rewind and inspection of the roll. This is serviced by a full room 2.5 ton gantry crane.
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