In-Line Coating Application

1. In-Line Coating Application Presented by: Thies Janczek

2. Content • Introduction • Technology • Advantages • Economical • Technological • Current Applications • Summary Customer Presentation

3. Core Print Overlay IntroductionLaminated card Overlay Print on Mono-Core Print • PrintMaterial (PVC) in thicknesses of 200 to 760 µm in a special grade of white.split core with 2 printing sheets ormono core – 1 sheet printed both sides Core • Printingmulti color litho, UV curing • Overlay - special adhesive coating. • Coreonly in 6-layer constructions Customer Presentation

4. Overlay Print IntroductionLaminated card • The printing is creating a layer between the PVC (or other thermoplastics), therefore an adhesive is mandatory for a good lamination result. • Today this adhesive is applyed • On the overlay in web coating by the material supplier. • On the print sheet, in screen printing by the card manufacturer • Alternatively: Apply with the coater on the litho press! Customer Presentation

5. TechnologyFlexo Coater on litho press • Typical Anilox system of the OEMs • Tresu, DK • Harris and Bruno, USA • Typically used for top coats (< 20% utilization at most card manufacturer) Customer Presentation

6. TechnologyFlexo Coater on litho press • Scheme of a flexo coater. • Advantage in a thicker material layer that can be transferred. • Anilox characteristics should be carrying a volume of >20bcm ADHESION IS A FUNCTION OF ADHESIVE THICKNESS AND UNIFORMITY Customer Presentation

7. TechnologyWater based on a litho press • Main point: The coating has to be dry as it is delivered to the stack. • Water based adhesive dries by air flow across the coated surface. • Air knife – low investment, easy to achieve. • Blow units are standard in many machines. • Transparent coating does not interfere with the final curing of colors. Customer Presentation

8. Hard meets Hard The hard adhesive is pressed onto the cured litho colors in the laminating press. As the temperature increases the adhesive melts, flows and performs the bond to color and substrate. Liquid meets Soft The liquid adhesive is applied onto the pre-cured litho colors. Instant wetting of the whole surface and a leveling out effect. Good penetration into micro-crevices and voids increase even the bond between UV color and substrate Overlay Printsheet TechnologyDry versus Wet adhesive Customer Presentation

9. Bond to inconsistent print sheet surface Need for good flow properties cause distortion effects Hot melt melt-temp does not change Bond to consistent overlay surface Only low flow properties are needed Heat started x-linking raise melt-temp  permanent bond Printsheet TechnologyAdhesion after Lamination Overlay Effect exaggerated Customer Presentation

10. Advantages- Ecological • Material cost saving • Just uncoated overlay needed • Artwork with low ink coverage w/o adhesive, i.e. just text artworks w/o bleeding over the card edge do not need adhesive. • Higher utilization of Equipment • Longer value-added chain • Pigmented adhesive for special effect w/o additional silk screen step Customer Presentation

11. Advantages- Ecological • Example calculation per laminate: • Conditions (most probable) • 50µm standard PVC Overlay • 5µm coating thickness • 48 cards per sheet (size 620x520mm) • SAVE more than 17 cent per laminate Customer Presentation

12. Advantages- Calculate your numbers Customer Presentation

13. Advantages- Technological • Process under own control • Utilization of existing Equipment • Low investment for air knife (< € 5000) • Neglect able process costs • Higher bond strength • Increased adhesion of the litho color to the substrate • Environmental friendly material/process Customer Presentation

14. Advantages- Technological • Decreasing lamination time and/or temperature • When all interfaces are coated, e.g. mono core with inline adhesive coating or in split core one print sheet coated on the center side. • Increased output • Better adhesive uniformity • Overlay independent Customer Presentation

15. Current Application • WINK Adhesive application on Litho presses with an Anilox coating station (OEM either TRESU or Harris & Bruno) • Same WINK formulation for screen application is employed as a primer and as adhesive (back up solution) • Pearl effect pigment dispersed in adhesive matrix for adding value to the cards Customer Presentation

16. Scenario ROI on a stand alone coater Simple calculation for an overview: • Estimated invest: 130.000 € • Saving per card: 0,36 €cent • Annual production: 200 Mio cards • ROI is under 2 years (22 months) Customer Presentation

17. Summary • On existing coating capacity very low investment. • High cost savings compared to other material/process options • Established process in the industry • High reliability, good process control, and high bond strength • Added-value chain for card producer Customer Presentation

18. In-Line Coating Application ANY QUESTIONS ? CONTACT US ! COCASO – Thies Janczek – Moewenstrasse 5a – 24113 Molfsee – Germany Phone: +49-(0)4347-703526 – Email : janczek@cocaso.com www.cocaso.com OR FUNCTIONAL MATERIALS INC. – Josef Feldman – 150 Route 17 - Sloatsburg, NY 10974 USA – Phone: +1-845-753-6000 – Email: info@functionalmaterials.com www.functionalmaterials.com Customer Presentation

19. Customer Presentation