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| There are a number of different methods coaters can use to apply coatings. Their choice is predominately driven by the type of coatings being used and the substrate being coated. Target markets, economic conditions, environmental regulations and other factors also play a role in determining how best to coat material.
Coil coating remains one of the most efficient coating processes for metallic webs. The variety of decorative and functional finishes are virtually unlimited. The coatings may be decorative, functional and/or protective. The typical coil coating line uses rollers to apply the coatings in a process that is similar to printing. However, lines can be designed with extrusion, knife or powder coaters. Coatings can be applied with gravure rollers to simulate wood grain patterns, create Logos and/or product information. Coatings can be embossed to provide textures. Organic films may be laminated to a metallic strip providing visual and physical properties not found in either material's free form. Similar or dissimilar metallic strips may also be laminated to create metal composites. These products provide unique structural or sound damping properties extremely valuable to the transportation, electronics and appliance markets. Each process lends itself to particular end products and markets. Any coater committed to a vigorous growth strategy must be knowledgeable in these processes to expand their customer base. There are a number of coil coated products that have large but very competitive markets. These markets are not always enjoyed by the widest and fastest coil lines. Labor productivity, operational efficiency and reducing manufacturing variation often helps those coil lines achieve more profitable results than their larger and/or better capitalized competitors. Reducing your labor, energy or quality component cost will help increase your market share in these products at improved margins. The Toll Coating segment of the industry is extremely risky for all but the most efficient coaters in the operation of their equipment. The cost of scrap and rejects can surpass original billings. Material cost could easily surpass 50% of revenue without a proper understanding of yield and how best to control it.
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