PRACTICAL GUIDE FOR COATING & CONVERTING IN INDIA

Reduce Coating Variation and Material Waste in Coating & Converting

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Cover of the Mahlo engineering field guide
Five practical steps from offline sampling to continuous inline quality control.
For plant, production, quality and engineering teams operating coating, laminating and relevant converting lines in India. Use a line-specific framework to find coating blind spots, quantify material exposure and define what reliable inline data should support on your line.
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Created for professionals responsible for process stability, quality consistency and material efficiency.
02
COATING & CONVERTING IN INDIA

A Sample Is a Snapshot. Your Coating Process Is Continuous.

Offline testing remains essential — but the coated web keeps moving between samples.

Offline and laboratory tests remain essential for detailed analysis, calibration verification and formal release. Inline web gauging adds repeated measurements across the working width and over time, helping operators see when and where coating weight or layer thickness moves.

Four loss paths to quantify

01

Coating give-away

More adhesive, lacquer, primer or functional coating than the application requires.

02

Functional tolerance risk

Too little or too much coating can affect adhesion, barrier properties, release behavior, sealing, printability or customer performance.

03

Start-up and changeover loss

Additional time, web length and material before stable coating weight and profile are reached.

04

Rework and downstream impact

Sorting, reprocessing, laminating issues, converting problems or customer complaints.

Two measurement perspectives

05

Across the working width

Where across the web is the deviation? Repeated cross-machine profiles add the spatial view.

06

Between the samples

How much coated web is produced before corrective action? Trends add the time view.

Not every line experiences every loss. Quantify the current exposure first. Only then estimate the value of better measurement.

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03QUALISCAN QMS

Measure. Document. Control — Where the Application Supports It.

Once the task is clear, match measurement principle and automation level to the actual application.

Qualiscan QMS provides a modular framework for measuring, logging and — where the application and line support it — controlling coating weight, layer thickness or another validated web parameter across the working width.

Continuous web process with highlighted cross-machine profile informationAI-generated image
01

Measure

Continuous profiles and trends show when and where the selected coating parameter moves.

02

Document

Store trends, roll data and process history for analysis, traceability and customer discussions.

03

Control

Feed validated measurements back to compatible actuators when process dynamics and integration support it.

Closed loop is not the default answer. It requires a stable measurement relationship, suitable response time, controllable process variables and integrated actuator capability.

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04INSIDE THE COATING & CONVERTING GUIDE

Five Steps to a Better Coating-Control Decision

Application first. Sensor second.

Use one product on one line. Diagnose first, specify second, and validate the technical and economic case with your own data.

  1. 01
    MAP

    Understand the application

    Describe the coating line, substrate, coating chemistry, process window, target range and tolerance.

  2. 02
    LOCATE

    Identify the exposure

    Find where delayed information creates material, quality or customer exposure.

  3. 03
    DEFINE

    Define the measurement task

    Translate the priority risk into the parameter, profile coverage and data output that matter.

  4. 04
    MATCH

    Match the technology

    Choose measurement principle and automation level only after the application task is clear.

  5. 05
    VALIDATE

    Validate with line data

    Test technical feasibility, quantify the baseline and build low, base and high economic scenarios.

What does 1 g/m² of unnecessary coating cost your line? The guide includes a worksheet using annual coated area, estimated avoidable excess and coating cost. Not all exposure is technically addressable.

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05COATING & CONVERTING APPLICATION FIT

What Should You Actually Measure?

Start with the priority parameter, the required profile information and the process phase where faster feedback matters.

The right configuration depends on the substrate, coating chemistry, layer structure, measurement range, line layout and required data output.

Production and quality specialists assessing a continuous coating and converting lineAI-Generated Image

Define the measurement task

  • PARAMETERCoating weight or layer thickness
  • PARAMETERFunctional coating parameter, where inline measurement is technically feasible
  • PROFILE & TRENDCross-machine profile
  • PROFILE & TRENDMachine-direction trend
  • PROCESS PHASEStart-up and changeover behaviour

Required output

  • Live operator feedback
  • Alarms
  • Historical trends
  • Quality records
  • Control-loop data, where suitable

There is no universal sensor for every coating. Validate the measurement principle against the substrate, coating chemistry, layer structure, line conditions, installation and calibration requirements.

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06ONE US CUSTOMER CASE · REPORTED RESULT AND METHOD

More Consistent Adhesive Coating

Spinnaker, USA. One documented label-coating application, shown through its reported result and application setup.

Spinnaker produces label stock. In this documented application, Mahlo evaluated the products, prepared product-specific calibration curves and applied inline measurement to improve coating consistency.

LABEL COATING · REPORTED RESULT

Spinnaker

>50% lower coating variation*

The documented customer result was a reduction in coating variation of over 50% for this application.

US customer case · application-specific

PRODUCT TESTING · APPLICATION CALIBRATION

Same application

Test. Calibrate. Verify.

Products were tested at Mahlo, product-specific calibration curves were prepared and an IMF-15 solid-state infrared sensor was applied.

Same customer application · transferable method

*Customer-reported result from one specific US label-coating application. Not an independent study, an India result or an expected outcome for other lines. Validate the measurement task, products and calibration for the actual application.

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07QUESTIONS BEFORE YOU DOWNLOAD

Questions About Inline Coating Measurement

No. Offline and laboratory measurements remain important for detailed analysis, calibration verification and formal release. Inline web gauging adds repeated measurements across the working width and over time.

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08ONE LINE. ONE PRODUCT. ONE QUALITY CHALLENGE.

Is Your Coating Line Worth a Closer Look?

Request a 20-minute Coating & Converting Quality Review.

No generic sales presentation. Prepare these five inputs for a focused discussion:

  1. 01Line and process
  2. 02Substrate and coating
  3. 03Target and tolerance
  4. 04Current checks
  5. 05Suspected loss point

Bring the application data. Build the decision together.

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