Optimizing Inline Coating Application
Since 1985,
XDS Holdings, Inc., an affiliate of
JB Machinery, Inc., has specialized in high-performance drying and curing systems for web-fed markets. Our innovative technologies, such as
inkPRO™ precision ink control and
irAIR®+ infrared drying systems, help corrugators and converters maximize quality, productivity, and efficiency in both inline web printing and barrier or specialty coating applications.
Advantages of Barrier Coatings
Barrier coatings offer significant benefits for corrugated packaging by protecting both the packaging and its contents from moisture, grease, oil, and other environmental factors. As the industry increasingly adopts lighter-weight materials and higher levels of recycled fiber, the demand for coatings that not only protect but also
enhance board strength continues to grow.
Because corrugated packaging is prized for its recyclability, coatings that interfere with fiber recovery or contaminate the recycling stream face growing scrutiny. As a result, water-based coatings are gaining favor among brand owners as an environmentally responsible alternative to polyethylene, wax, and solvent-based coatings. These next-generation coatings help maintain the sustainability of corrugated packaging while delivering essential barrier performance.
Optimizing the Coating Process with Inline Corrugator Application
As demand for eco-friendly coatings increases, converters are seeking ways to
streamline coating processes and
maximize throughput without sacrificing quality. Inline coating
on the corrugator, rather than a secondary offline operation, offers the most efficient and cost-effective approach.
Inline application reduces equipment needs, conserves floor space, minimizes handling and logistics, and lowers energy costs. By combining coating and corrugating into a
single-pass operation, converters can send sheets directly from the corrugator to the converting line, therefore reducing total production time.
Optimum Throughput, Maximum Efficiency
For peak efficiency, coating application and drying must seamlessly integrate into the corrugating process. XDS delivers this through systems such as
inkPRO and
irAIR+ with
AutoDryer Control™, which together provide precise, automated control of both coating and drying.
Inkpro precision ink and coating control
inkPRO eliminates constant operator oversight by automatically managing coating temperature, viscosity, and pH. The system continuously monitors coating parameters and makes fine adjustments in real-time to maintain optimal consistency. When adjustments are required, inkPRO precisely doses chemical additives—avoiding overuse, reducing waste, and stabilizing performance. By automating these functions, operators can focus on higher-value production tasks, while the system prevents pH and viscosity swings that cause coating variations, color shifts, and inconsistent drying.
irAIR+ with AutoDryer Control
The
irAIR+ infrared drying system further enhances coating performance by minimizing drying times and enabling higher corrugator speeds. Its zoned control design provides unmatched production flexibility, adapting to a variety of laydown and coating requirements. The integrated
AutoDryer Control (ADC) system virtually eliminates operator guesswork. ADC analyzes key process variables (substrate, coating type, speed, and environmental factors) and automatically adjusts power levels to maintain the ideal surface temperature. The result is consistent, efficient drying with reduced power consumption and minimized operator intervention.
Flexibility for Changing Market Demands
Modern packaging production demands adaptability. With shorter runs, rapid design changes, variable liner/flute combinations, and evolving coating chemistries, drying systems must be
versatile and responsive.
As coatings continue to transition from solvent-based to
water- or bio-based formulations, drying characteristics shift—lower VOCs and slower evaporation rates require more precise and efficient heat management. Achieving optimal results under these conditions calls for
custom-engineered drying solutions, not one-size-fits-all equipment.
For four decades, XDS has been at the forefront of
customized, high efficiency drying systems that deliver safe, reliable, and repeatable performance.
Tailored Solutions for Evolving Operations
XDS understands the complex needs of today’s corrugators and converters. Our systems are engineered for seamless integration, ensuring consistent, optimized performance and maximized efficiency run after run. Each solution is designed to meet your current production demands and adapt as your market and mix evolve.
Jeff DeVries
President
jdevries@teamxds.com
920-722-8123
teamxds.com
