Pilot Coating & Development

Carestream’s precision multilayer coating expertise and unique product development capabilities help customers enhance product offerings. Our pilot coating facilities enable customers to utilize coating trials to quickly adjust formulation and conditions for low-cost, small-run and experimental roll-to-roll coating projects.

Pilot Coater 1

  • Single layer coating with three stations per pass with front and backside configurations
  • Solvent and aqueous coating including chlorinated solvents
  • Slot/extrusion coating
  • 8 to 25 fpm
  • Corona Discharge Treatment (CDT) available
  • 2″ to 17.5″ coating width on 2.5 to 14 mil substrates

Pilot Coater 2

  • Gravure, mayer rod, 1-2-3 roll (forward and reverse), slot die, slide and polishing bar
  • Solvent and aqueous coating
  • CDT, UV curing, and lamination available
  • 10 to > 200 fpm
  • 4″ to 12″ coating width on 0.5 to 10 mil substrates
  • Two independent temperature controlled oven zones
  • 100% optical inspection

Lab Scale

  • Handspreads, sample coater and small scale roll to roll coater for 12″ wide substrates
  • Homogenization
  • Automated coaters
  • Reaction vessels





  • DOE, statistical analysis
  • Test method development

Full Support

  • PhD Chemists
  • Synthetic, Organic, and Analytical Chemists
  • Formulators
  • Engineers
  • Fabricators

Carestream Coating Assessment Lab

  • Rapid material and product screening
  • Small product sample coating and coating-assessment-lab2testing
  • Efficient scale-up to pilot and production coating equipment

Areas of Expertise

  • Solution formulation and characterization
  • Solution mixing and delivery
  • Substrate characterization
  • Coating methods and operating window
  • Drying and curing
  • Coated sample testing
  • Microscopy/Analytics
  • Process modeling for coating and drying
  • Pilot coating trials


  • Rheology and viscosity
  • Static and dynamic surface tension
  • Density, solids and particle size analysis
  • Mixing and dispersion studies-high/low shear mixing, homogenization, inline mixing, etc.
  • Filtration and pump selection
  • Substrate testing-dimensional stability, mechanical testing, surface characterization, and thickness and uniformity
  • Fluid engineering for coating application
  • Assessment of viable coating methods

Faster time to market

Using the same resources to execute development and scale-up enables Carestream to deliver world-class development-to-production cycle times.

Lower investment costs

Our pilot facilities feature flexible assets for development work and a wide array of coating capabilities.


Pilot coating enables customers to conduct small-scale production runs with the ability to quickly test and implement changes—without the drawback of having to stop production.


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