Contract Coating / Film Coating

Do you need to optimize capacity or expand your product portfolio? Send us your specifications.

Coating
  • Thickness:
    <1 micron - 50 micron
Substrate
  • 0.25 - 20 mil
  • 24" - 80" wide
Method
  • Gravure coating:
    Direct, Offset, Reverse
  • Slot die coating

Contract Coating Overview

Dunmore is a leading partner for the development and contract coating of engineered films, foils and fabrics. Dunmore's contract coating delivers your proprietary technologies with our 50+ years of web handling expertise. On-site process engineers and Dunmore's development process enable us to quickly scale the production of your coated substrate on our equipment.

Whether you’re looking to maximize capacity, add functionality or test new technologies, Dunmore's scalable film coating manufacturing capabilities enables quick delivery to market for startups to Fortune 100 partners.

Toll Coating Specialties:

  • Precision coating / Gravure coating
  • Multi-layer coatings
  • Disparate coatings & laminations

U.S. Toll Coating Specifications

Roll to Roll Coating

Coating Technologies
  • Single head coating
  • Double head coating
  • Two side coating (C2S)
  • Direct gravure coating
    • Kiss coating
  • Reverse gravure coating
  • Offset gravure coating
  • Slot die coating
Chemistries
  • 0.25 g/m2 - 50 g/m2
  • Thickness: <1 micron - 50 micron
  • Aqueous coating
  • Solvent coating
  • UV coating

Substrate Handling

Film
Foil
Fabric
  • 0.25 - 20 mil (film)
  • 0.36 - 8 mil (foil)
  • 24" - 80" wide
  • Up to 40" outside diameter
  • 3", 6", 10" cores

Drying Capabilities

Oven
  • Up to 400°F
  • Multi-zone
  • Roller driven

Additional Web Handling

  • Auto splicing for high efficiency and productivity.
  • Expertise in handling multiple polymeric substrates.

European Toll Coating Specifications

Roll to Roll Coating and Laminating

Coating Technologies
  • Single head
  • Direct gravure coating
    • Kiss coating
  • Indirect gravure coating (offset)
  • Reverse gravure coating
  • Closed pressure gravure coating
Chemistries
  • 0.25 g/m2 - 50 g/m2
  • Thickness: <1 micron - 50 micron
  • Aqueous coating
  • Solvent coating

Substrate Handling

PET
BOPP
PE
Fabric
Nonwoven
Paper
  • 12 - 500 micron (PET)
  • 30 - 200 micron (OPP)
  • 30 - 200 micron (PE)
  • 0.60 - 2.50 meter wide
  • 1200 mm outside diameter winder
  • 1000 mm outside diameter let-off
  • 3", 6" cores

Drying Capabilities

Oven
  • Up to 150°C
  • Multi-zone
  • Air impingement

Inline Quality Assurance Systems

  • Optical defect detection 3 cameras in transmission, 3 cameras in remission
  • Web cleaning systems (contact and non-contact)
  • Viscosity control

Additional Web Handling

  • Auto splicing for high efficiency and productivity.

Advanced Film Coating

Our dedicated solutions team, coupled with our extensive web handling capabilities, are coordinated to provide quick, custom material conversions; enabling us to assist in the creation of new products in unison with our customers, existing operations and systems.

Dunmore offers timely film coating solutions utilizing all of our resources to meet our clients' custom processing needs. We develop partnerships with our customers by delivering unparalleled toll coating expertise and superior attention to detail. Maintaining solid, long-term partnerships built on trust and maintaining complete confidentiality are two of Dunmore's core values when working on toll coating and gravure coating projects.

Typical Coating Functionality

  • Antiblocking
  • Antimicrobial
  • Antistatic
  • Barrier
  • Blackout (Light Filtering)
  • Chemical Resistant
  • Conductive
  • Corrosion Resistant
  • Decorative / Custom Colors
  • Embossable
  • Eraseable / Writable
  • Etchable
  • Flame Retardant
  • Hardcoats
  • Heat Resistant
  • Heat-Seal
  • Insulative
  • Matte
  • Opaque
  • Print Receptive
  • Release
  • Scratch Resistant
  • Security / Custom Logos
  • Slip
  • Transparent
  • UV Blocking

Typical Substrates

  • Acrylic
  • Fabrics
  • Foil
  • Kevlar®
  • Nomex®
  • Nylon
  • Polycarbonate
  • Polyester
  • Polyethylene
  • Polyimide
  • Polypropylene
  • Polystyrene
  • Polyvinyl Chloride
  • Resin Coated Paper
  • Scrim
  • Synthetic Paper
  • Tedlar®
  • Teflon®
  • Tyvek®
  • Woven and Non-Woven

What is Toll Coating

Toll coating is a commonly used term in the film coating and converting industry. Toll coating refers to when an organization uses a third party to coat their materials, instead of doing it themselves. The company that utilizes a third party toll coater will often supply the flexible substrate and chemistry to the toll coater. They pay the third party coater a “toll” to process the material. A company uses a toll coater when they are experiencing demands that exceed their manufacturing capacity. A company will also look for toll coating companies when they do not have the internal coating capabilities required for a project. Common coating methods used for toll coating projects include gravure coating and slot-die coating.

Contact Us for Your Toll Coating Project

Please contact us to find out more about our contract coating capabilities in the United States and Europe.