Heavy-Duty Knife Coater for High-Viscosity Coatings | Fully Customizable Knife-Over-Roll Coating Machine
Price:
Negotiation
MOQ:
1 set
Delivery Time:
30-45days
Brand:
OSMANUV
Product Description
Heavy-Duty Knife Coater for High-Viscosity Coatings | Knife-Over-Roll Coating Machine for Rubber, Adhesive & PVC – Customizable
Product Overview
A knife coater (also known as a knife-over-roll coater or doctor blade coater) is a versatile coating machine that applies a precise, controlled layer of liquid or paste-like material onto a moving substrate. The coating thickness is determined by the gap between a doctor blade (knife) and a backing roller or the substrate itself.
This technology is ideal for high-viscosity coatings (500 - 100,000+ cP) that cannot be easily applied by roller or curtain coaters. Typical coating materials include:
- Adhesives (PSA, hot melt, solvent-based)
- PVC paste (plastisol)
- Rubber compounds (latex, SBR, natural rubber)
- Battery electrode slurries (anode/cathode)
- Ceramic slurries
- Flame retardant coatings for textiles
- PU (polyurethane) coatings
- Silicone release coatings
Technical Specifications
| Parameter | Standard Range | Customizable Option |
|---|---|---|
| Coating Width | 500 mm / 1000 mm / 1300 mm / 1600 mm | ✔ Yes (up to 3000 mm) |
| Line Speed | 5 - 50 m/min (standard) | ✔ Yes (up to 150 m/min) |
| Coating Thickness (wet) | 20 - 500 µm | ✔ Yes (up to 2000 µm) |
| Viscosity Range | 500 - 50,000 cP | ✔ Yes (up to 200,000 cP with heating) |
| Substrate Type | Paper, film, nonwoven, textile, foil, rubber sheet | ✔ Yes (any flexible material) |
| Substrate Thickness | 0.02 mm - 5 mm | ✔ Yes |
| Knife Type | Knife-over-roll, air knife, floating knife | ✔ Yes (interchangeable) |
| Backing Roller | Chrome-plated steel / rubber-coated / stainless steel | ✔ Yes |
| Coating Material | Adhesive, PVC, latex, PU, ceramic slurry, battery paste | ✔ Yes |
| Drying Method | Hot air (electric/gas) / IR / UV | ✔ Yes (multi-zone custom) |
| Tension Control | Open-loop / closed-loop load cells | ✔ Yes |
| Power Supply | 380V / 400V / 415V, 50/60Hz, 3-phase | ✔ Yes (custom voltage) |
| Control Type | PLC + HMI touchscreen | ✔ Yes (remote control optional) |
Key Applications
- Battery manufacturing: electrode coating (lithium-ion anode/cathode slurries)
- Adhesive tape & label: PSA (pressure-sensitive adhesive) coating on release liner
- Textile & nonwoven: flame retardant, PU coating, latex backing, waterproofing
- PVC flooring & artificial leather: PVC paste coating on fabric or release paper
- Rubber sheet & gasket: rubber compound coating on fabric or release film
- Ceramic & green tape: ceramic slurry coating for multilayer capacitors (MLCC)
- Paper & packaging: silicone release coating, hot melt adhesive coating
- Construction materials: asphalt / bitumen coating for roofing membranes
Customization Options
- Working width: from 300 mm (lab/pilot) to 3000 mm (industrial)
- Knife type: knife-over-roll, air knife, floating knife, or knife-on-blanket
- Backing roller material and hardness: chrome, rubber, stainless steel
- Coating head positioning: manual micrometer or automatic servo-controlled gap adjustment
- Drying oven: length, number of zones, heating method (electric/gas IR + hot air)
- Web path: horizontal, vertical, or combination
- Cleanroom class: ISO 5/7/8 for battery or medical applications
- Explosion-proof design for solvent-based coatings
- Integration with upstream (mixing, degassing) and downstream (slitting, laminating) equipment
- Automatic viscosity control with inline viscometer
- Edge masking system for stripe coating
Key Features
- Precision gap control - repeatable coating thickness to ±1-3 microns
- Heavy coating weight capability - up to 2000 µm wet (customizable)
- Wide viscosity range - from 500 cP to 200,000+ cP with heated knife/roller
- Quick knife change - for different coating materials or thickness ranges
- Easy cleaning - knife and backing roller accessible from both sides
- Automatic thickness feedback (optional) - closed-loop control via online gauge
- Heated backing roller (optional) - for hot melt or temperature-sensitive coatings
- Low coating waste - minimal startup and edge loss
- Sturdy construction - heavy-duty frame for vibration-free operation
- Recipe storage - recall coating parameters for different products
Support and Services
- Free coating trials - we test your material in our lab on a pilot knife coater
- Process optimization support - we recommend knife type, gap, speed, and drying parameters
- On-site installation and commissioning (optional)
- Operator and maintenance training (on-site or video)
- 12-month warranty + lifetime remote technical support
- Fast spare parts supply (knives, backing rollers, pumps, thermocouples)
- Annual service contract with preventive maintenance
Frequently Asked Questions
Q: What is the difference between a knife coater and a roller coater?
A: A knife coater is better for high-viscosity, thick coatings (e.g., PVC paste, battery slurry). A roller coater is better for lower viscosity. We can customize either type or combine them.
Q: Can I coat both sides of a substrate?
A: Yes, we offer customizable two-sided (dual-head) knife coaters with sequential or simultaneous coating.
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Get in Touch
Have questions about our products or want to discuss a custom order? Our team is ready to help you.
Company
Dongguan Osmanuv Machinery Equipment Co., Ltd
Location
28 the second industrial, Liu chong wei , Wanjiang ,DongGuan , Guangdong, China
Contact Person
Zhang guoxin