Slot Die Coating Systems

Die Fluid Delivery Systems

Ensure proper coat weight by filtering the coating fluid and providing consistent, non-pulsating pumping with a metered fluid delivery system. EDI combines standard components into a fluid delivery system that is matched to your process and equipment, including:

Gear pump, progressing cavity pump, or pressurized vessel (size and type selected based on your specifications) The pumping system designed to minimize the introduction of air into fluid during operation and can be explosion proof.

Custom cart on which the system is mounted so it can be easily moved and cleaned.

All necessary pressure indicators and air purge ports.

Filtration system with cartridge-style filters.

Fluid delivery hoses and three-way valves at die inlet (designed to minimize clean-up from spills, including valve location to avoid spills on cart).

Die Modular Coating Systems (MCS)

Switch readily between roll and slot die coating or use slot die coating on a trial basis with EDI's Modular Coating System. Each MCS is custom designed to your requirements and typically includes a fluid-delivery system, an adjustable support for positioning the die lip with respect to the web, idler rolls, and a precision backing roll. These components are unitized within a steel frame for support, and casters allow it to be rolled.

Die Support Systems

Position the coating die at the best possible angle and proximity to the roll with a support system specially built for Ultracoat slot dies. This provides the accuracy and repeatability that are essential, given the tight operating windows for backup roll applications.

Die Wetware™ Systems

Test your theories on the production line. The Liberty WetWare system combines die, positioner, pump, and ancillary components into one module for on-site slot die coating trials on actual production lines. EDI equipment readily adapts to coating lines made by a variety of manufacturers.

Initial meeting is held to review current process, establish desired process outcomes, and set a schedule. We ship all the equipment to your production site, and an EDI Senior Application Engineer is on-site for set-up and coating trials at a time convenient for you (1-2 days). The trial will demonstrate the feasibility of using the fixed lip slot die coating method and determine your system requirements.

Die Positioners

Establish accurate positioning with a die positioner, and achieve successful coating applications that can be consistently repeated. The positioner ensures the slot die is in proper position relative to the substrate being coated. The backing roll itself remains fixed and is typically included with the positioner to ensure greater precision.

In a standard Liberty positioner, the primary positioned movement is along a line running through the slot in the die toward the roll center. This horizontal movement provides:

On-Coat and Retracted positions (to initiate or end a coating)

Splice Jump position (for splices to pass through the gap)

Precision adjustment of coating gap, between die lips and substrate, using differential screws

Liberty Slot Die Handlers Option
Fixed lip slot dies are precision devices that must be handled with care. Avoid damage to die cavity, land, and lips with a simple, labor-saving die handler. You can quickly and easily split the die, clean it, change shims, and bolt it back into place— all without removing the die from the positioner! The die handler will also help you remove the die from the positioner when necessary.

Die Vacuum Systems

Remove the air and control the coating bead with a vacuum system. Fixed lip slot die coating applications work best when air is removed from the area where the coating is flowing onto the substrate. The vacuum box seals against the lower portion of the backing roll, against the bottom half of the die, and at each end. The remainder of the vacuum system is used to evacuate the box and to ensure that any excess coating at the beginning or end of a coating run is collected and kept from the blower.

Distribution Blocks & Adapters

Whether you require a small transition plate, a sophisticated distribution block for routing multiple flow streams to multi-channel dies, or a lengthy feedpipe network, we pay the same attention to detail as we do for all dies. Distribution blocks and adapters are:

Designed based on flow streamlining and engineering safety

Machined from high-quality steel forgings

Hand polished with the same quality finish as extrusion dies

Autoflex™ Technology

Installed on more than 2,300 dies worldwide, EDI's Autoflex automatic lip adjusting system is the premier technology for precisely controlling the thickness profile of the film. In addition to making possible higher quality, more accurate products, the Autoflex system can generate substantial raw material savings compared to conventional manual adjustment.

The most recent evolution is Autoflex VI, with an available thermal stroke range of +/- 0.015" (+/- 380 microns). The thermal translator blocks are mounted above the die body to eliminate thermal "cross-talk" between the die body temperature control zones and the Autoflex system. The Autoflex VI is also available as a removable module that can readily be disengaged from the die as one complete unit for fast and easy maintenance, known as the Autoflex VI-R.

View Autoflex brochure. »

Layer Multiplication (Multiplier) Technology

Obtain the substantial property enhancements of micro-layer structures in a way that is easier to deploy, more compact, more accurate, and far more versatile than any other layer multiplier system.

Tooling based on the new design can be supplied for applications over a large range of widths and has been used successfully for a 171-in. (4.3 m) product. The system can be engineered to multiply materials from three, five, seven, nine, or more melt streams.

Install the layer-multiplier tooling in an existing extrusion line with only minor modifications. The downtime required for cleaning out the system can be as little as four hours, as compared with a much longer period (as much as a week) with other systems. Plus, the advanced layer multiplier is available without licensing or royalties.

UltraCart™ Cleaning & Maintenance Systems

Enhance worker safety, reduce downtime, simplify die disassembly and reassembly, and prevent costly damage to critical die surfaces during maintenance. UltraCart systems will streamline your cleaning procedures, because the system allow the die halves to be easily rotated to access flow surfaces.

Basic UltraCart System is designed for single-manifold dies.

UltraCart Rapid Servicing System is designed for multi-manifold coextrusion dies. Fully mechanized, the system can be wheeled to the processing line for off-loading of the die and moved to a workplace for die cleaning and maintenance. Technicians can offload, disassemble, clean, reassemble,
and return the die to operation – all without removing die components from their secure mounting on the cart.

View Ultracart cleaning and maintenance systems brochure. »

Die Carts

Safely support your extrusion die while it is in operation with a horizontal mounting die cart. Design your cart to help you work more efficiently; include an operator's platform or supports for other items mounted close to the die (e.g., feed pipes or screen changers).

Deckling Systems

Deckles are adjustable devices that vary end product width by blocking off portions of the die slot from both ends of the die. EDI offers a wide range of external and internal types.

External deckling systems include: fixed-side deckles, flex-side deckles, sliding cantilevered wedge-style deckles, and Fast Deckle™.

Internal deckling systems include: EPC™ full internal/external deckle with edge profile control and EPC-R™ partial internal deckles (lip-land blades) for edge profile control. Both internal deckling options are available in motorized systems.

UltraSplit™ Online Die Separation Device

Eliminate the downtime required to disconnect the die, move it to and from a cleaning station, and then heat it up again to resume production with this easy to operate system. Plus, avoid the safety and damage concerns involved when moving a heavy extrusion die.

The UltraSplit separation device frames the die as it operates online, splits the die halves, and orients the die bodies to provide access for cleaning flow surfaces. The device consists of:

a support system with brackets to suspend the lower die body

perpendicular horizontal frameworks on both sides that incorporate drive shaft (manual or motorized) for moving the flex die body back and forth

mounting assemblies to permit pivoting of the upper die body

To operate the system, first remove the body bolts and flip a switch to start the motor that separates the die bodies (or use a hand crank to separate them manually). Hand-operated levers applied to the trunnions easily pivot the flex body to provide access for cleaning.

View Ultracart cleaning and maintenance systems brochure. »

Dual Chamber Vacuum Boxes

Achieve better stabilization of extruded film with a Dual Chamber Vacuum Box than with other web-impingement devices. A pre-sweep chamber removes the entrained air between the surface of the casting roll and the film. A second chamber develops a higher vacuum that stabilizes the film forming area, reduces neck-in, and controls the movement of the film's edge.

To simplify cleaning, maintenance, and installation, the Dual Chamber Vacuum Box is constructed of stainless steel and features a swing-out, split chamber. Various blade configurations, adjustable at the pre-sweep section as well as between pre-sweep and primary chambers, can be supplied.

View dual chamber vacuum boxes brochure. »

EverSharp™ Lip Edge Technology

Improve product quality while gaining several whole days of added machine uptime each year with EDI's innovative system for coating flat-die lip surfaces. The technology is based on tungsten carbide coating, which lasts eight times longer than the standard chrome plating used for flat die lips. Compared with chrome-plating, EverSharp lip edge technology is substantially more resistant to micro-fractures during initial sharpening, abrasion during normal use as well as cleaning, and corrosion.

Purge Blocks

Carry out die maintenance while the extruder is temporarily shut down but still full of polymer by incorporating a purge block between the extruder and the die. The purge block acts as a valve, blocking flow from the extruder while purging material from the die.

UltraLip™ Scraper

The UltraLip Scraper System centers on two lip scraping assemblies for the upper and lower lip faces, respectively, that move in unison across the width of the die along threaded drive screws. The screws can be operated from either side of the die by using a simple hand crank or drill to activate a cable drive system. Typically, the operator cleans the die face during production prior to starting a new roll. The scraped-off debris falls onto the web at the end of the roll, and that end is subsequently cut from the roll as scrap. Advantages of this system include: operators can clean the die face without interfering with production; increased safety for operators; avoiding burns incurred while reaching across the width of the line to clean debris from the lip face; toggle tension system allows for system to be re-calibrated; and lip scraper blades can easily be replaced if they become damaged or worn.

FastDeckle™ Technology

Designed for adjusting width during operation, this heavy-duty, external deckling system accommodates high extrusion rates. A single-point adjustment at each end of the die actuates a wedge clamping device for seal engagement. The deckle assembly swings out to permit easy access to seals at the die ends. The FastDeckle system is available for retrofitting on older dies.

FastGap™ Lip Adjustment System

A mechanism that allows for single-point adjustment, this system makes it possible to adjust the position of the movable lower lip of the die, varying sheet thickness within a range of 0.250 in. (6.4 mm) without taking the die off line. A die equipped with a FastGap system on its lower lip operates on the principle of separate lip responsibilities. An additional 0.100 in. (2.5 mm) is available with the top lip of the die, which controls the transverse gauge profile. Together, these capabilities increase the range of gap adjustment from the previous maximum of 0.100 in. (2.5 mm) to 0.300 in. (7.6 mm). The adjusting device used by the extrusion-line operator to activate the FastGap system is equipped with a micrometer-like gauge which precisely indicates gap settings.