Investing in cutting edge technology

Coating, metallizing and laminating of polyester films specialist Hanita Coatings has installed a state-of-the-art Laem System slitter rewinder. Part of the Israeli company’s $11M expansion programme the equipment was successfully commissioned in January, reports R&D manager Dany Eisenstadt, who also had responsibility for managing the whole project.

The custom built TR550 equipment was specifically designed to handle delicate coatings and exposed metallization at high speeds. The 2.1m wide centre driven slitter is tailored to the company’s label facestock production.

Hanita’s recent investment included a 3,400m² manufacturing facility at its Western Galilee based facility, which houses a new SAM 2.1m wide coater laminator whose production is handled by the Laem slitter rewinder. The new SAM line features advanced production techniques, improved production speeds, and enhanced levels of cleanliness, and will boost both the company’s window film and label facestock production. It allows the production of wider width material in greater volume. New processes such as atmospheric plasma, inert UV, controlled shrinkage and enhanced heat stabilization deliver superior coating adhesion, new coating formulations and increased dimensional stability, claims the company.

“Before we made this investment we were operating at nearly our maximum capacity. It was starting to affect our delivery times,” explained Dany Eisenstadt. “Now we will double our production within the next five years and it also allows us to develop additional technologies.”

“We’re very satisfied with the slitter’s smooth performance so far,” he states. “Its computer controlled systems are providing consistently high quality slit rolls and accurate winding, at speeds that can reach 400m/min. Add to that its quick change-over capabilities, and we’re finding that the equipment is really improving production efficiency, as well as winding quality.

“We chose Laem System because of the technical capacity and the flexibility of design that can answer our requirements. It was also a pleasure to work with such a good converting equipment company,” he adds.

“Its equipment can handle gauges from six to 250 micron film and will support our production of window film as well as the label facestock. Our production is very diverse over one shift. We may use different slitting techniques, for example razor and shear cut, we can change materials and we can change slitting widths. Widths may be 1.5m, 1.4, 1.6, 300mm or just edge trim.

“And we can do other things – other processes which we would rather not talk about at the moment,” he reveals. “Loading, unloading and knife setting is controlled by the operator.”

In the original plant next door the technological portfolio includes a Leybold 2.1m vacuum roll coater. Hanita Coatings’ metallizing capability includes patented methods of reactive deposition, using the Leybold to coat films with aluminium, copper and other metals, oxides and alloys. On the coating front, in addition to the SAM, the company boasts a Kroenert 1.6m wide coater, an Egan 2.1m wide coater and an Egan 0.7m wide pilot coater, a cleanroom facility and other slitting capacity. The warehouse has 6,000m2 storage capacity. Coating techniques include direct gravure, reverse gravure, Mayer rod, reverse roll, comma coating, pressurized enclosed chamber, in line corona treatment, atmospheric plasma, UV radiation curing – atmospheric and inert, pre-shrink treatment and heat stabilization. Typical coatings include print receptive, abrasion resistant, anti static, nanoparticle, UV block, lacquers, heat activated and pressure sensitive adhesives and top, buried and dyed colour.

Hanita Coatings exports almost all of its production – some 97 per cent, says Dany Eisenstadt. “Our main market is Western Europe, but other markets such as the Far East and the United States are growing quite well too.” All its base polyester film is imported. “We use the right quality of materials at the right price,” he says.

The recent investment also includes the purchase of an additional vacuum roll coater scheduled to be running by the end of the year. Dany Eisenstadt is not prepared to reveal the name of the supplier at this time.

“And there is space in the new facility for another new coater laminator if and when it is needed,” he reveals.