Complete high speed, wide width coating and lamination production capacity 20 Million running meters per year + for SOLAR & BATTERY Industry Applications

(DPR) presents a comprehensive, brand‑neutral, and model‑neutral assessment for setting up a high‑speed, wide‑width coating and lamination production line. The facility is designed for lamination of PET with PVF/PVDF substrates, primarily suitable for advanced technical films such as solar industry applications, lithium‑battery related films, electrical insulation films, and other functional laminated films.

The DPR is structured to meet the requirements of banks, financial institutions, investors, EPC contractors, and government authorities, and is suitable for subsidies, project finance, or internal approvals.

B. Project Overview

• Project Type: Greenfield / Brownfield Expansion (configurable)
• Technology: Continuous coating, drying, and lamination
• Product Category: Advanced technical laminated films
• Operation Mode: Continuous, multi‑shift industrial production

C. Product Description & Applications

C.1 Input Substrates

• PET film: 125–300 μm
• PVF / PVDF films: 15–50 μm

C.2 Finished Product

• High‑performance laminated technical films

C.3 End‑Use Applications

• Solar module backsheet and functional layers
• Lithium‑ion battery insulation and protection films
• Electrical & electronic insulation
• Specialty industrial laminated films

D. Manufacturing Process Description

D.1 Process Flow

1. Primary substrate unwinding
2. Optional corona treatment
3. Optional dust removal
4. Infeed and closed‑loop tension control
5. Precision micro‑gravure coating
6. Multi‑zone hot air drying oven
7. Web guiding and stabilization
8. Thermal lamination with secondary substrate
9. Cooling and dimensional stabilization
10. Web accumulation
11. Final rewinding

D.2 Working Principle

The primary substrate is coated using precision gravure technology. The coated web passes through a multi‑zone drying system to remove solvents and cure the coating. A secondary substrate is laminated under controlled heat and pressure. The laminate is cooled, accumulated, and rewound into finished rolls.

E. Technical Configuration (Indicative)

• Max Mechanical Speed: 80 m/min
• Nominal Working Speed: 60 m/min
• Max Web Width: 1350 mm
• Drying Length: 40 m (multi‑zone)
• Max Oven Temperature: 180 °C
• Coating Method: Micro‑gravure reverse coating
• Installed Electrical Load: ~155 kW (excluding heating system)

F. Production Capacity Assessment

F.1 Basis of Calculation

• Working speed: 60 m/min
• Operating hours: 24 hours/day
• Operating days: 300 days/year
• Overall operational efficiency: 85%

F.2 Capacity Calculation

• Production per hour: 3,600 meters
• Effective production per day: 73,440 meters
• Annual production capacity: ≈ 22 million running meters per year

Actual output may vary depending on product structure, coating weight, substrate thickness, and changeover frequency.

G. Utilities Requirement

G.1 Electrical Power

• 3‑Phase, 380 V, 50 Hz
• Voltage tolerance: −10% / +5%

G.2 Compressed Air

• Pressure: 7 bar ±1 bar
• Oil‑free, dry, filtered (<20 μm)

G.3 Cooling Water

• Pressure: 0.15–0.25 MPa
• Temperature: 20–25 °C
• Consumption: ~200 L/min

G.4 Heating System

• Thermal oil or equivalent heating medium
• Boiler, piping, valves, and insulation in buyer/EPC scope

H. Plant Layout & Infrastructure

• Approx. line length: 50 m
• Heavy‑duty reinforced foundation
• Controlled clean workshop environment (100,000 class)
• Provision for material handling, maintenance access, and safety platforms

I. Automation & Control Philosophy

• PLC‑based centralized control
• Multi‑HMI operator interfaces
• Closed‑loop tension control across sections
• Servo and vector inverter‑driven sections
• Integrated alarms, interlocks, and data logging

J. Quality Control & Process Stability

• Online tension and edge position monitoring
• Stable drying temperature control (±2 °C)
• Consistent lamination pressure and nip temperature
• Repeatable coating weight control

K. Safety, Health & Environment (SHE)

• Emergency stop system (<5 s shutdown)
• Full guarding of rotating and pressing parts
• Static elimination systems
• Explosion venting and negative oven pressure
• Provision for LEL and solvent exhaust systems

L. Environmental & Regulatory Considerations

• Solvent handling with controlled exhaust
• Compatibility with VOC abatement systems
• Noise level ≤ 85 dB(A)
• Compliance with local industrial safety regulations

M. Installation & Commissioning

• Foundation readiness verification
• Mechanical erection and alignment
• Electrical and utility hook‑up
• Cold and hot trials
• Performance acceptance tests
• Operator and maintenance training

N. Manpower Requirement (Indicative)

• Operators: 4–6 per shift
• Shift supervisor: 1 per shift
• Maintenance & utilities: shared team
• Quality control: 1 per shift

O. Project Risks & Mitigation

P. Financial & Commercial Framework (Indicative)

• Capital cost: Equipment + utilities + civil + installation
• Operating cost: Power, manpower, consumables, maintenance
• Revenue driven by product mix, coating weight, and market pricing

Q. Implementation Schedule (Typical)

• Engineering & final design: 2–3 months
• Manufacturing & procurement: 6–8 months
• Site readiness: Parallel
• Installation & commissioning: 2–3 months
• Commercial production: ~9-12 months from order