What are the fluid handling capabilities?
What are the web handling capabilities?
What are the coating capabilities?
What are the drying capabilities?
What is the approach to product quality?
What substrates can be coated?
Can the substrate be treated before coating?
What is the experience with aqueous polymer systems?
Can MCT make proof of concept? Or prototype trials?

What are the fluid handling capabilities?
Our capabilities include preparing solvent-based or aqueous-based fluids, adding components to closed vessels, and mixing batches from 5 to 3000 gallons (mixes above 100 gallons are computer controlled). We offer strict temperature control from 10 to 100 degrees Celsius, closed system dispensing with built in multi-stage filtration and degas capability, and unique and proprietary methods to safely handle shear sensitive fluids. Our proprietary in-line real time bubble detection system facilitates bubble elimination and particle size reduction, and vacuum degassing preserves batch composition. We use attritors, dynomils and sandmils to grind aqueous dispersions, homogenizers and colloid mills to make oil-in-water emulsions, and microfluidizers to de-aggregate.

What are the web handling capabilities?
At core sizes of 3 inches, 6 inches, or 10 inches, we can apply coating to both sides of the product in a single pass without surface contact throughout the web path. In a Class 400 or higher clean room environment, we accurately track coating widths from 13-65 inches, manage substrate thickness from 0.75 – 30 mils, and maintain precise operation from 30-500 fpm (with a maximum OD on rewind of 40 inches). Most importantly, our web-driven process and vacuum pull rolls eliminate the danger of scratches due to nip rolls or slippery drives, guaranteeing against the contamination or wear of the substrate while being coated.

What are the coating capabilities?
With up to six stations with lamination and UV curing capabilities, we can slot die, cascade, gravure, or roll coat any side of the product with any fluid. We can coat solvent, aqueous, UV curable, or 100% solids, and our vacuum-assisted application extends the operating window for the coatability of fluids. Our just +/-2% variation across the width and down the roll means our pre-metered coating process can be configured to efficiently handle all products from the simplest to the most complex, and our 100% online laser web inspection ensures process control. We handle viscosity from 1 to 8,000 CP and dry film thickness from 40 nm to several mils, with a UV curing capability of up to 1500 watts/inch. Static and dynamic in-line blending of fluids immediately prior to application point and the heating and/or cooling of fluids and coating heads during operation preserve these measurements and prevent compositional alteration during the coating process.

What are the drying capabilities?
We provide a wide range of drying configurations, from quiescent to aggressive, with an operating temperature of up 270 degrees Fahrenheit. With built-in web temperature measurements, each dyer has four 25-ft. zones independently controlled for humidity and dew point during drying, and can increase its length by up to 500 ft. without face contact.

What is the approach to product quality?
By developing robust processes, we integrate quality assurance into our entire manufacturing operation. In addition, we offer 100% on-line IR inspections as a real time process control tool, as well as routine sampling and testing. Our product testing is supported by world-class analytic capabilities, including SEM, HPLC, FTIR, and Near IR; particle size characterization; X-ray fluorescence; rheology characterization; the use of sensitometry, colorimeters, environmental chambers, and ovens; and the careful control of pH, viscosity, and titration.

What substrates can be coated?
At a thickness from 0.75 to 30 mils, we can coat polyethylene terephthalate (PET), polyethylene napthalate (PEN), oriented polypropylene (OPP), bi-axially oriented polypropylene (BOPP), polyimide (PI), polyetherimide (PEI), paper (plain and clad), cellulose acetate, polycarbonate, and metalized substrates. We utilize a casting base for peel coatings and treat the substrate according to your manufacturing needs.

Can the substrate be treated before coating?
Prior to coating, we can apply various chemical tie coats (silanes, etc.) and corona treatments (5 KW) to promote adhesion, utilize subbing layers (gels), and conduct contact and non-contact web cleaning according to your specifications.

What is the experience with aqueous polymer systems?
We have extensive experience with PVA, gelatins and latexes.

Can MCT make proof of concept? Or prototype trials?
Our 5-inch lab coater and pilot capabilities beginning at 12 inches facilitate early production on widths from 12-65 inches, and we put our trademark Polaroid process engineering expertise to work for your most stringent development and production requirements.