Film casting
Film casting
World-leading thin film casting process
IPCO is an experienced cast film line manufacturer – our film casting systems combine process versatility with precision engineering to enable the efficient production of films, tapes, and membranes to extraordinary levels of accuracy.
Whatever your end application, however challenging the product tolerances, we have the casting film system and process expertise to help you get there.
Continuous production of high precision thin film, tape or membrane
Our film casting process ensures reliable production of high quality thin film, tape, and membrane materials essential to industries ranging from energy and electronics to pharmaceuticals, food, and biomedical. We design and manufacture high productivity film casting and coating solutions for all these applications and many, many more.
Our thin film solution casting method delivers a homogeneous layer of liquid product onto a steel belt with outstanding consistency of thickness as it passes through our steel belt casting and drying system. The cast layer is transported on the steel belt through one or more drying units to deliver a stable, high quality product in an extremely efficient manner.
Our roll to roll coating methods include slot die, knife, comma bar and a wide variety of roll coaters. Our systems include features such as precision web handling and automatic tension control. For extremely fine substrates, we offer a coating process with the support of a belt rather than a throwaway carrier.
This combination of high precision casting or coating, world-leading steel belt technology, and a range of different drying solutions – including our unique Venturi drying system – means we can help you meet the most demanding thickness and flatness tolerances.
Film casting
Range
5–500 μm
Film thickness
Accuracy
+/- 1 K
Heating/cooling
Energy efficiency
Up to 85%
Belt heating efficiency
How it works
Our solutions
We supply custom engineered and fully integrated production solutions incorporating everything needed for the solution casting process for producing polymer film, from casting, heating, and drying stages to calendering equipment, slitting and winding solutions, and all necessary utilities.
Casting and coating for thin film
A heated slot die or coating roller delivers a uniform and homogeneous casting of the product onto a moving steel belt for continuous casting. High precision engineering and a small gap between the die and belt means the thickness profile of the film can be set to precise tolerances.
Polished steel belt
We produced the world’s first steel belt more than 120 years ago and remain a world leader in steel belt technology to this day. Our polished steel belts are manufactured to a thickness accurate to within ±10 µm and we can supply polishing grades to deliver a surface as fine as Ra <±0.1 µm.
Drying and evaporation
The liquid casting layer is transported through a series of controlled phases. This involves heat and mass transfer in the evaporation process or a controlled phase separation process in a precipitation section.
Venturi dryer
Venturi drying is a technology unique to IPCO for this application. It delivers a homogeneous drying effect that eliminates any risk of skin formation, resulting an end product of exceptionally high quality, with low stress and virtually no risk of fault and imperfections.
Benefits
Why choose IPCO to support you in casting thin films
Custom engineered, fully integrated systems
For ceramic tapes and edible, water soluble and optical films
Production solutions to suit your application
Dry film thicknesses from 5-500 μm
Unique Venturi dryer – eliminates risk of skin formation
Outstanding precision and reproducibility
Our five Productivity centers offer exceptional testing, R&D, and process assessment facilities
Portfolio showcase
Delivered by our solutions
Chocolate forming systems
IPCO’s chocolate moulding systems enable cost-effective production of high quality industrial and decorative chocolate products.
Cooling systems
IPCO’s cooling lines combine steel belts with highly efficient air and/or water cooling systems to deliver rapid, controlled solidification.
Drying systems
IPCO’s dehydration systems enable quick, hygienic, and energy efficient drying of wide range of fruit and vegetables.
Drum granulation systems
We offer the highest capacity units available to produce formed sulphur to SUDIC specifications, embodying the best of granulation technology.
Double belt presses
IPCO’s modular double belt presses can seamlessly integrate numerous processes into one continuous system, for efficient production at scale.
Extrusion systems
IPCO’s high-performance twin-screw extruders combine outstanding throughput rates with easy access for rapid product changes.
Freezing systems
IPCO’s steel belt-based freezing systems deliver rapid freezing, maximum hygiene, and consistently high product quality.
Material handling
Our bulk material handling solutions encompass everything from conveyors and elevators to storage and loading systems.
Oil skimmer conveyor
IPCO’s oil skimmers use steel belt technology to enable quick, continuous, and effective extraction of oil from water.
Powder coating forming systems
Transform raw mixes into perfectly cooled flakes ready for milling. Harness our unparalleled expertise in cooling, flaking, and extrusion to achieve the flawless finish you envision, time after time.
Rotoform systems
IPCO’s Rotoform technology handles pastillation with ease and precision, from complex chemicals to food.
Scattering systems
IPCO’s oscillating and rotating brush-off systems deliver versatile and precise scattering for powders, granules, fibers, chips, flakes, and other materials.
Steel belts
Since 1901, our steel belts have been the backbone of industrial efficiency, driving reliability and performance in every process we’re part of.
Spray systems
Innovative design allied with precision engineering to achieve dramatic improvements in the application of release agents onto press belts.
Thin film casting systems
IPCO’s high precision thin film casting systems enable the production of film products to exceptionally narrow tolerances.
Venturi dryer
Effortlessly evaporate solvents and perfect your film casting process with our innovative, tension-free drying technology.
Engage
Explore IPCO
Industries
We use our expertise in each industry to design cutting-edge production equipment that meets our customers’ needs.
Processes
We make industrial processes smoother and more efficient, for today and tomorrow.
Solutions
We create innovative solutions that reliably deliver our customers’ productivity goals.
Service and support
Our global presence ensures that no matter where you are, your manufacturing technology can keep performing at its best, thanks to top-tier service and expertise locally.
Get in touch
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