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Customizable Modular Roller Coating Production Line for Pulp Molding with High Material Efficiency and Precision Coating
Product Overview
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 Specifications
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)
Stainless steel
--
Safety Features
Light curtain, emergency stops, enclosure interlock, over temperature protection
Customizable per factory requirements
Compliance
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
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
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: Change between product families or coating formulations in <5 minutes—ideal for flexible manufacturing
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
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 from 12 to 36 stations via bolted turntable sections—expandable for future capacity upgrades
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 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%.
Q4: What is the minimum order quantity (MOQ)?
We accept single unit orders (MOQ: 1 set). Volume discounts are available for customizable batch configurations or multi-unit orders.
Company Details
Bronze Gleitlager
,
Bronze Sleeve Bushings
and
Graphite Plugged Bushings
from Quality China Factory
Business Type:
Manufacturer
Year Established:
2007
Total Annual:
2000000-3000000
Employee Number:
150~200
Ecer Certification：
Verified Supplier
Dongguan OSMANUV Machinery Equipment Co., Ltd. was established in 2007 and is headquartered in Dongguan, Guangdong Province, a renowned manufacturing hub within the Guangdong-Hong Kong-Macao Greater Bay Area. We are a high-tech enterprise integrating R&D, production, sales, and af... Dongguan OSMANUV Machinery Equipment Co., Ltd. was established in 2007 and is headquartered in Dongguan, Guangdong Province, a renowned manufacturing hub within the Guangdong-Hong Kong-Macao Greater Bay Area. We are a high-tech enterprise integrating R&D, production, sales, and af...
