Customer Outcomes
Better intra/inter-batch consistency, higher yield, faster ramp; 100% full-width defect coverage with traceability.
Configuration & Modules
Casting/Coating: slot-die, comma bar, micro-gravure; 3–6 drying zones with dew-point/airflow control; roll-to-roll tension map & EPC.
Thickness/Areal Weight: β/X/laser cross-web scans + down-web trends; NIR areal dose with gravimetric cross-checks.
Slitting/Die-cutting: precision slitter-rewinder; rotary/flatbed dies; static control, edge trim take-up; in-line coding & seal checks.
Vision Inspection: 4K line-scan with coaxial/backlight/diffuse; detects pinholes, contaminants, scratches, wrinkles, wander, registration, color drift; optional OCR/2D codes.
Operating Window & Throughput
Width 300–800 mm; web speed 0.5–8 m/min; drying 40–60 °C; target thickness 30–120 μm (typ. 40–90 μm).
Tolerances: die-cut ±0.2 mm; registration ≤±0.3 mm; burr ≤0.05 mm.
Quality & Data
Thickness/defect heatmaps tied to lot; SPC/Cpk dashboards with alerts; on/offline calibration; retain IDs with photo evidence.
Integration
Barcoding/serialization, lot QR, data export (CSV/JSON); LIMS/MES/ERP hooks; optional Part-11-style e-signatures/audit trails.
Risks & Mitigations
Curl/brittleness: tune plasticizer & dew-point; add stress-relax zones.
Blocking: moisture & winding tension control; anti-blocking measures.
Hydroalcoholic safety: EX-proof, ventilation, LEL interlocks, residual-solvent control.
Client Inputs
Target thickness/size/batch size & tolerances; defect acceptance criteria; coding rules; packaging type & barrier targets (WVTR/OTR).