HOW TO: Dual Layer Plasma Release Coatings for Curing Oven Rollers

Published: May 03, 2024

Any interruption in today's manufacturing process results in lost time, product, and profitability. Web defects, inconsistent tension, and buildup on roller surfaces are often at the top of the list of causes of these interruptions. Battling these issues can be a monumental task at times.

Most web substrates today are either treated, coated, laminated, or converted in some way to provide a unique performance factor for the end user. Prepping or curing the substrate can have multiple processes. Roller positions are critical to support and guide the web as it travels through the oven while thermally curing. Any defect or buildup on the roller's surface can create scrap product, especially with sensitive web substrates.

As an example, during adhesive coating or curing in ovens, rollers are in contact with the web while the adhesive is still in an "uncured" wet or tacky state. If the roller surface has slightly more affinity for the adhesives or chemistry, build-up can occur. If the buildup is too great, the web can become riddled with defects or even break. When an event like this occurs, the loss in production and product can be alarming.

Operators do their best to address buildup issues on rollers during preventative maintenance by manually cleaning, usually with strong solvents. This can be dangerous and environmentally hazardous. Traditional Teflon can be applied on rollers in spray form or by sleeving to improve the condition. However, most of these surface treatments are short lived, and if one small area becomes exposed, the coating becomes ineffective very quickly.

Dual Layer Plasma Coating systems offer a truly non-stick surface, providing release for incidental or direct contact conditions. The base metal matrix is penetrated with the release polymers during the application, maximizing the wear and life of the roller. The surface can be 58 - 72 Rockwell C in hardness adding critical durability for extended life and performance. Plasma Coatings can also be applied on-site, at your facility, in most oven configurations during an extended down period.

Today's Plasma Coating Systems continue to advance the science of release and wear resistance together as one. Consult with your Plasma Coating representative and ask, what is new vs just a few years ago?

William R. Bradley Jr.

Vice President, Business Development American Roller

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262.878.8665