Gap-Controlled Rollers with 0.001 mm Accuracy
At the heart of the system are coating rolls with precision gap control down to 1 micron (0.001 mm).
The rolls are mounted in a rigid, vibration-isolated frame and controlled by high-resolution adjustment modules. This ensures:
- constant layer thickness along the entire width,
- elimination of “wave” defects or streaking,
- perfect reproducibility for long production series,
- stability even when the substrate expands or contracts thermally.
The roll geometry and surface finish are engineered specifically for advanced materials: conductive pastes, slurries, thermally activated adhesives, ceramic formulations, silicone emulsions or polymer-based coatings.
Integrated with KEPKA Tunnel Furnaces Coating Meets Heat Treatment
KEPKA Coating Roll Systems are not standalone machines. They are designed to operate as part of a continuous thermal line in which:
- The coating is applied via precision rolls.
- The substrate enters the tunnel furnace immediately after coating.
- The furnace stabilizes viscosity, activates adhesives or cures functional layers.
- Cooling or conditioning modules bring the material to the required handling temperature.
- In-line cutting or rewinding units complete the process.
This integration ensures that the coated material behaves predictably throughout the entire process — without shrinkage, edge curling, bubble formation or thermal distortion.
Tunnel furnaces in these lines are configured to provide uniform convection heating, often with multi-zone control, ensuring that every millimeter of the coated layer experiences the same thermal environment.
This is essential for battery materials, TIM layers, optical films, technical foils and polymer laminates used in high-precision assemblies.
Integrated Tunnel Furnace Systems for Curing, Cooling and In-Line Finishing
KEPKA delivers fully integrated coating roll systems combined with tunnel furnaces for the curing and thermal stabilization of coated materials such as thermally conductive mats, silicone foams and thermal interface materials (thermal pads). These solutions are engineered as continuous production lines, where precise coating application is immediately followed by controlled thermal processing.
After coating, materials enter a multi-zone tunnel furnace designed for uniform convection-based curing. Dynamic airflow ensures consistent activation of binders and coating layers across the full material width, while preventing surface defects, internal stress or material collapse — critical for soft, elastic and heat-sensitive products.
Dynamic Cooling and In-Line Cutting with Edge Trimming
Following the curing stage, the material is transferred into dynamic cooling sections, where controlled airflow and heat exchangers stabilize geometry and lock in functional properties. Once cooled to the defined handling temperature, the product proceeds directly to in-line cutting systems, which perform precise cutting of the finished material “in flight”.
These cutting modules are designed to produce final sheet dimensions with high accuracy, while integrated edge trimming systems remove excess material from both sides of the web. The result is a finished product ready for packaging or downstream processing, without additional manual operations.
Complete End-to-End Coating Lines
By integrating coating rolls, tunnel furnaces, cooling modules and in-line cutting with edge trimming, KEPKA provides complete, end-to-end solutions for high-volume production of functional materials. The entire line operates under unified control, ensuring repeatability, efficiency and minimal operator involvement. Such systems are widely applied in the production of thermal pads, battery protection materials, insulation foams and advanced composite sheets used in energy, automotive and electronics applications.
Thermal Stabilization for Sensitive Substrates
Coated films and foils require precise temperature control to achieve target properties.
KEPKA integrates thermal stabilization stages that gently transition the material through controlled convection, minimizing internal stress and preventing geometric distortions. Whether the process requires drying, curing, activation, gelation or heat sealing, our systems ensure that:
- temperature gradients are smooth,airflow is controlled and uniform,
- the coated layer remains intact,
- the substrate maintain dimensional stability.
These stages can be configured as chamber sections or continuous tunnel zones depending on production speed and substrate type.
Applications Across EV, Energy, Electronics & Advanced Manufacturing
KEPKA Roll Coating Systems are used in industries where coating thickness, surface quality and thermal stability define final product performance.
Typical applications include:
- battery electrode coatings and protective films,
- EV thermal-management pads and separator layers,
- ceramic slurry deposition for technical components,
- adhesive and release-liner coatings,
- optcsite pre-preg coating,
- EMI s
- hielding layers,
- lamination-ready polymer sheets.
Summary
KEPKA Roll Coating Systems combine ultra-precise mechanical engineering, gap control down to 0.001 mm, synchronized thermal processing and stable downstream handling. By integrating coating rolls with tunnel furnaces, cooling modules and finishing stages, we deliver complete, fully controlled solutions for industries where coating thickness, uniformity and thermal precision are mission-critical. These systems are ideal for cutting-edge applications in EV, battery materials, electronics, optics and advanced manufacturing.
