Solventless lamination is becoming more common in flexible packaging and roll-material converting because it reduces solvent use and supports cleaner production. But the process also needs tighter control. If the adhesive coating amount is too high, material cost rises and curing may become unstable. If it is too low or uneven, bonding quality can suffer. At the same time, the surface may still show visible defects such as streaks, bubbles, contamination, scratches or missing coating.
Bainary can combine coating amount tracking with visual inspection on the same production line. CTS3.0 focuses on adhesive coating amount changes and process data. The visual inspection system focuses on visible surface and print-related defects. Together, they help operators see both the coating condition and the web surface condition instead of relying only on manual sampling.
Where this application fits
- Solventless flexible packaging lamination lines
- Adhesive coating and laminating lines
- Paper-plastic and film-paper composite materials
- Label materials and release film coating
- Protective film, functional film and other roll-to-roll coated materials
- New energy and industrial film coating processes where coating amount and surface quality are both important
Typical production issues
- Adhesive coating amount is too high, too low or unstable across time.
- Coating weight changes are discovered too late through offline sampling.
- Uneven coating, streaks, bubbles or missing coating affect later lamination quality.
- Visual defects and coating amount problems are checked by different methods and not easy to connect.
- Operators need a faster way to judge whether the line should continue running or be adjusted.
How Bainary helps
- CTS3.0 monitors coating amount changes online and records process data.
- The system is designed for glue and coating applications where operators need fast feedback, not only laboratory results after production.
- Visual inspection can be added to detect visible defects such as streaks, stains, bubbles, scratches, missing coating and surface contamination.
- Data records help the production team review when a coating fluctuation or surface defect appeared.
- The solution can be configured according to material type, web width, line speed and inspection position.
Recommended Bainary systems
- CTS3.0 Coating Quality Tracking System
- CV300 coating / adhesive monitoring sensor head
- OK8000 or OK6000 visual inspection system, depending on web width and defect requirements
- Web guiding and tension control systems if web stability affects coating or lamination quality
- Thickness or width measurement systems when the process also requires dimensional monitoring
What we need to confirm before selection
- Material structure, such as film/film, paper/film or label material
- Adhesive or coating type
- Web width and normal line speed
- Expected coating amount range
- Current sampling method and main pain point
- Defect types to be detected visually
- Available installation space near the coating or laminating section
- Whether data export, alarm output or connection to another system is needed
Get in Touch
Send us your material structure, web width, line speed and current coating control method. Bainary can help decide whether to use coating amount tracking alone, visual inspection alone, or a combined coating and visual inspection solution.
