KKA Kleinewefers has extensive experience in the flooring industry. KKA offers turn-key flooring production lines for the commercial and residential market. KKA flooring lines allow manufacturers to operate efficiently and profitably, and also be flexible in order to provide innovative products.
PVC floor covering is a product with a multilayer structure and is produced on a continuous KKA flooring line consisting of foam coating, top coating, lacquering, and applying a backing to a carrier material such as a glass fiber or polyester nonwoven substrate. The flexibility of KKA coating and printing lines ensure an easy and fast change of product layers and print patterns.
Generally, a distinction is made between CV (cushioned vinyl) flooring and compact floor coverings. Various fields of application include residential housing, schools, hospitals, offices, public buildings, retail stores, and gyms.
KKA Kleinewefers offers adhesive coating and laminating lines for adhesive films and tapes, protective films, adhesive labels, technical papers, insulation, and silicone papers. A typical adhesive coating line consists of an unwinder, a coater such as a knife-over-roll coater or a melt-roll coater, a drying oven, a let-off and laminating station for the release paper, and a wind-up. KKA adhesive coating lines have high production rates (up to 400 m/min) with minimal variation of the coating thickness. The use of coating weight measuring system and automatic closed-loop control of the coater adjustments guarantee highest product quality.
Coating is the most common finishing process for web materials, and KKA offers a wide range of coating technologies. This includes reverse-roll coaters, knife-over-roll coaters, floating knife and kiss-roll coaters as well as melt-roll coaters for polymer based adhesives.
Technical textiles are based on a textile fabric as a substrate and then coated with a material dependent on the application. KKA Kleinewefers coating lines for technical textiles generally consist of coating the textile fabric on both sides, such as with PVC, and then applying a lacquer top coat on both sides. Coating can be done with either conventional coating equipment or with a melt-roll calender. Coating weights can range from 80 up to 2,500 g/m². In addition to coating, other key technologies offered by KKA include laminating, embossing and lacquering.
Uses of technical textiles include architectural and construction fabrics, tarpaulins, tear-proof advertising banners, tents, awnings, swimming pool liners and covers, supported structures, sporting equipment, and boat covers.
Hot melt coating lines from KKA Kleinewefers are used in the manufacture of tapes, labels and a wide range of adhesive laminates for automotive and nonwoven applications. Hot melt coating can be used on foil, film, foam and on release liners.
One of the main advantages of hot melt coating is that they offer a cost-effective solution for many coating requirements. They are easy to set up and use. No dryer is required, which means hot melt coating lines have low energy and low space requirements. They use water-free and solvent-free adhesive, thereby making them environmentally friendly. Low coating weights down to 20 g/m² are possible.
KKA can supply hot melt coating lines with either roll coaters or slot-die extrusion heads.
Thin PE films are often used in hygienic products, and these films are usually micro-embossed. In order to emboss PE film at high speed, KKA Kleinewefers developed a special embossing calender. The desired embossing can only be achieved with exact temperature control, and this is done by heating in stages. In order to maintain the depth of the pattern in the film, the film is precisely cooled and transported to the take-up winder with even tension.
KKA Kleinewefers is a well-known supplier of coating lines for producing high quality PVC, PUR and TPO artificial leather used in automobile interiors. Coating lines for artificial leather typically include multiple coating stations followed by laminating a scrim fabric and embossing a grain or 3-D effect into the artificial leather and finishing with a top coat. The result is a multi-layer composite structure resembling leather.
Embossing the material gives the desirable appearance. In the embossing station the material is pre-heated with infinitely adjustable infrared heaters and then heated by a main cylinder which ensures a very precise temperature profile across the web of ±1 ⁰C. Embossing is effected in the embossing calender between hot and cold embossing rollers. After embossing, the material is tempered and cooled. The embossing calender is designed so that the embossing rollers can easily be changed.
Efficient lithium-ion batteries are probably the most promising technology for the mobile energy supply of the future. Compared to other battery technologies, environmentally-friendly energy carriers show substantial advantages. They are used in regenerative drives in hybrid vehicles and as stationary accumulators for power from wind and solar energy.
KKA Kleinewefers provides coating and casting lines for the anode, cathode and separator elements for lithium-ion batteries as well as for lithium polymer and nickel metal hydride batteries. Various materials are used for the anode, cathode and separator elements such as nickel foam, thin copper film, thin aluminum film, and expanded metal.
KKA Kleinewefers offers continuous and intermittent coating lines with safe nitrogen atmosphere dryers.
Roofing membranes consist of a fabric scrim coated on both sides with a thermoplastic polymer such as PVC, CPE or TPO. Roofing membranes can also be coated with cross-linking (or vulcanizing) thermoset polymers. Many of the synthetic rubbers (EPDM) fall into this category. Thermoset membranes tend to be thicker than thermoplastic membranes.
The polymer coating can be applied to the fabric scrim with either a flat extrusion die or with KKA Kleinewefers’s MRC (melt roll coating) technology. The advantages of MRC technology over flat extrusion die coating are that there is less waste during color or formulation changes, parameters such as coating width and coating thickness can easily be changed, there is lower thermal stress, and it can be easily cleaned because it is an open system.