Barrier Coating Frustration
Presented by:
Tony Lyons
Director of Research
Most Aqueous Coating Defects Can Be Traced
to the Following Root Causes:
COATING PITS
DEFECT DESCRIPTION
Coating Pits - Defined as microscopic holes in the coating. Appearance can be enhanced by a
Croda Red stain.
SYNONYMS
ILLUSTRATION
Optical micrograph of a coating pit. Note how rounded the edges of the pit are.
≈ Defect Classification:
COATING PITS
CAUSES OF COATING PITS
FOAM STREAKS
DEFECT DESCRIPTION
Foam Streaks - Defined as relatively short 6 mm (0.25") [Brown says that they can be as short as
2-3 mm] long, extremely faint marks in the coated paper surface. About 3 mm (1/8") in width,
they are usually not in a straight line but tend to wander to one side or the other. Foam Streaks
on puddle type blade coaters are caused by air bubbles on the color surface in the pan riding
against the incoming web. Bubbles may ride back and forth and/or follow the web down into
color. Foam streaks on an applicator roll/trailing blade coater will line up with the roll split
pattern.
Foam Streaks are best seen when inspected at a very low angle and with low
angle lighting. They may or may not calendar out, and they may or may not show
up in the printed surface.
SYNONYMS
FOAM STREAKS
CAUSES OF FOAM STREAKS
REFERENCES
1. Brown, A., and Cruthoff, B., “A Pilot Coater Trial to Investigate the Occurrence of Coating Surface Foam
Streak,” TAPPI Coating Conference Proceedings, 2002.
Resolution
Customer discovered an open fall of coating from the make down tank
to the coating supply tank
Extend the piping to reduce the chance for air entrainment
It was also noticed that excessive foam was developing in the coating
make down tank
Contacted their coating additive supplier for a defoamer recommendation
that would not interfere with the barrier property they were after
Were able to achieve a marked improvement to 15 g/M2/day under
tropical conditions, but still not what they achieved in the lab
Customer invested in deaeration equipment to further reduce the pin
holes and now achieve about 8+\- 2 g/M2/day under tropical conditions
Thank you
PRESENTED BY
Tony Lyons
Director of Research
IMERYS
tonylyons@imerys.com