Converting Basics
Common R2R Converting Technologies
Once a substrate is on a roll, there are a number of different ways value can be added as it moves through a converting line. Most R2R operations rely on some combination of the following core technologies — often several in sequence on the same machine.
Coating
Mayer rod, knife-over-roll, slot die, gravure, reverse roll, curtain, and the fundamentals of coat weight and rheology.
LAMINATINGLaminating
Wet bond, dry bond, solventless, extrusion, and thermal lamination — how converters combine layers into one structure.
FINISHINGFinishing
Die cutting, embossing, perforating, scoring, and sheeting — the operations that bring a web to its near-final form.
TESTING & INSPECTIONTesting & Inspection
In-line measurement, vision inspection, coat weight gauging, tension monitoring, and off-line lab testing.
SLITTINGSlitting
Shear, razor, and score slitting — plus duplex, turret, and log slitter configurations.
PRINTINGFlexographic Printing
Flexographic press configurations, digital, screen, and offset printing used across R2R converting.
PRINTINGGravure Printing
Engraved cylinders, engraving methods, and why gravure delivers consistent density on long runs.
SURFACE TREATMENTSurface Treatment
Corona, plasma, and flame treatment — how converters raise surface energy for better adhesion.
METALLIZINGMetallizing
Thermal evaporation, e-beam, and sputtering — how converters deposit thin metal and oxide layers in vacuum.
WEB HANDLINGWinders & Unwinders
Shaft-mounted, shaftless, and turret unwinds; center, surface, and gap winding configurations.
WEB HANDLINGWeb Handling
Web path, tension, guiding, nip safety, and the defects that come from getting web handling wrong.
DRYING & CURINGDrying & Curing
Convection, infrared, UV, EB, and conduction — how converters take a wet coating to its final solid form.