Coating Machine

The coating machine applies a uniform layer of molten polymer across the surface of a large film roll, then dries the film in a furnace and finally rolls the film. (1) Feeder machine sets the long, heavy film sheet roll weighing several hundred kilos, (2) Coating head applies the liquid coating to the surface, (3) Drying furnace dries and hardens the film surface, (4) Hardener exposes the film to ultraviolet radiation to harden the film, (5) Roller winds the film onto a drum.
The Ena Plant has 3 lines (No. 1 to No. 3) and a test coater; Mizunami Plant has 1 line (No. 4). Both plants perform coating operations in a class 100 clean environment.
(Class 100 standard specifies less than 100 particles of 0.5µm size per cubic foot.)

Equipped Plants

• Ena Plant
• Mizunami Plant

• Specifications

  • Roller surface length: 1500mm to 1800mm
  • Line speed: 5m/min to 150m/min
  • Substrate thickness: 12µm to 250µm
  • Substrate width: Max 1700mm, Min 600mm

• 1. Roll Feeder

  Sets the film roll, and feeds the film into the machine.
  Mizunami Plant No.4 machine supports widths of 1700mm.
  The machine is equipped with two feed rollers so that protective or other film can be laminated and coated at the same time.

  

• 2. Coating Head

  Applies the liquid coating to the film surface.
  The head is housed in a class 100 clean environment.
  The coating head is a cassette type, where the cassette can be changed to rip coat, reverse coat, micro-gravure coat, according to the required product finish. No. 4 machine has two coating heads allowing it to apply two coatings in a single operation.

  

• Coating Methods

  • Rip coat
  • Reverse coat
  • Micro gravure coat
  • Other options

  

• 3. Dryer

  Dries the liquid coating applied to the film surface.
  Furnace uses floating method using circulating hot air for high-efficiency drying. No. 4 machine drying furnace is 43.5m in length and features high productivity.

  

• 4. Ultraviolet Irradiation Equipment

  Helps harden coatings, for materials that harden when exposed to UV radiation.
  Equipped with non-polarized lamps and high-pressure mercury lamps.

  

• 5. Take-up Roller

  Conducts inline inspection of the coating and rolls the coated film onto a reel.
  A second take-up roller is provided for simultaneous protective film lamination. Mizunami Plant No. 4 machine supports production of adhesive-type protective film.

  

• Other Ancillary Equipment

  • Defect detection equipment: permeability, reflectivity
  • Spectrophotometer: UV-visible spectrophotometer
  • Film thickness: Laser non-contact test
  • Source roll cleaning equipment: 2-step adhesive roller

  

Test Coater

• Coating test area

  Area for coating development and testing. Testing on actual manufacturing equipment is expensive in terms of material and running costs, whereas the test coater allows speedy coating tests using limited resources.

  

• Specifications

  • Roller surface length: 600mm
  • Line speed: 2 to 40m/min
  • Substrate thickness: up to 250µm
  • Substrate width: Max 500mm
  • Coating method: Cassette change method
  • Reverse, micro-gravure, rip, slot die

  

Equipped Plants

• Ena Plant

Aging Room

• Accelerates aging to simulate the coating curing and hardening over a given timespan.
  Higashiyama Film is equipped with aging rooms that maintain a 40°C to 60°C temperature range.

  

Equipped Plants

• Ena Plant
• Mizunami Plant

Clean Slitter

• Higashiyama Film is equipped with slitter machines that operate inside a clean environment.
  The roll film can be cut to an arbitrary width and length while being rolled. Clean environment operation is essential for products that are coated in a clean environment.
  Enables simultaneous slit and laminate processing.

  

• Specifications

  • Roller surface length: 1500mm to 1900mm
  • Substrate width: MAX 1800mm MIN 400mm
  • Maximum number of cuttings: 100mm × 10
  • Core diameter: 3 inches, 6 inches
  • Maximum diameter: Φ600mm, Φ750mm
  • Clean standard: Class 5000 (Ena Plant, Mizunami Plant)

  

Equipped Plants

• Ena Plant
• Mizunami Plant

Laminator

• Laminator affixes a thin protective film onto the substrate film. The protective film helps to prevent scratches and other damage. The Shanghai Plant laminator supports lamination on both sides in a single pass.

  

• Specifications

  • Maximum processing width: Substrate film 1120mm, protective film 1110mm
  • Substrate thickness: 50µm to 450µm
  • Core diameter: 3 inches, 6 inches

  

Equipped Plants

• Ena Plant
• Higashiyama (Shanghai) Function Film Co., Ltd.

Cutter（Roll to Sheet）

• Rolls out the film and cuts in into sheets.
  A machine is also available that remove curls from sheets that curl easily.

  

Equipped Plants

• Ena Plant
• Nagoya Plant
• Higashiyama (Shanghai) Function Film Co., Ltd.

Cutter（Trimming）

• Accurately cuts the film into arbitrary sizes.
  Used for printed film applied to switch components on electrical appliances. The printing process supports various sized film sheets.

  

• Specifications

  • Supports 50µm to 500µmのPET film and other plastic films, from 148mm × 210mm (A5) small sizes to (939 × 636mm) large sizes cutting with high dimensional accuracy.

  

Equipped Plants

• Ena Plant
• Nagoya Plant
• Higashiyama (Shanghai) Function Film Co., Ltd.

Slitter

• Continuously cuts the long, heavy roll film weighing several hundred kilos into longitudinal strips of arbitrary width and length. The size varies from a minimum of several millimeters to full width.

  

• Specifications

  • Width: 8.6mm to 1290mm
  • Thickness: 25µm to 400µm
  • Core diameter: 3 inches, 6 inches
  • Maximum reel diameter: Φ570mm

  

Equipped Plants

• Ena Plant
• Nagoya Plant
• Higashiyama (Shanghai) Function Film Co., Ltd.

Press (Cutout Machine)

• Punches film using metal die to form various shapes.
  Large-volume automated machines and large-sized manually-operated machines are used to meet various customer needs.

  

Equipped Plants

• Nagoya Plant
• Higashiyama Film (Shanghai) Co., Ltd.

Ultrasonic Welding

• Welds film using ultrasonic sound waves. Used to make insulating materials of various shapes, including caps that are welded on one side and S-tubes welded into a spiral shape.

  

Equipped Plants

• Nagoya Plant
• Higashiyama Film (Shanghai) Co., Ltd.

Dummy Molding Machine

• Dummy cans shown in display case of drink vending machines. These cans are actually printed PET film molded into the shape of a can. Higashiyama Film developed a triple-neck automated machine that uses a 3-step molding process to create different effects. We produce and market the dummy cans for vending machines.

  

• Film used in Vending Machines

  • Usually, we look at vending machines with just a casual glance. However, if one looks closely, they use various sales promotion goods. These are mostly made from printed film. A "top board" is affixed on top, a "poster" is displayed in the center, and a "small POP" (point-of-purchase advertising) is affixed to the dummy can.

  

Equipped Plants

• Nagoya Plant