There are any number of reasons why a company might set up a pilot coating line. These reasons typically include a need to:

• Develop a new coating process or product
• Optimize an existing coating process
• Troubleshoot a process
• Run preliminary checks on raw material lots or batches
• Manufacture a narrow web or expensive, small-volume product

The first question to ask yourself is the intended use. The objectives for the pilot line must be clearly understood before the unit is specified and installed. Will it be strictly for process/product development? If so, should it be flexible and easy to retrofit as new application methods or auxiliary devices are required? Will it be used for occasional production or product scale-up until a production coater is qualified or constructed or a contract coating house certified? These questions will be key in the design criteria such as web width and line speed.

Next, think about location: Pilot lines can be located within an R&D group and used mostly for development. They might be part of a coating manufacturing operation to support production and located nearby.

They might also be located in an equipment fabricators shop and used to support the development of specifications for a new coating line.

Many companies use their production lines to develop new products/processes. They jump directly from the benchtop to production with the associated risks in scaleups. The advantage of running these trials on a pilot line is the reduction of the "scale-up factor" when moving a process from the bench drawdown to production. In addition, by keeping the production line for production, manufacturing efficiency remains high and the risk of changeover losses from contamination and setup errors are minimized.

Manufacturing groups often want to optimize a current process to improve quality or yields. They also might want to troubleshoot problems without interrupting the manufacturing process. This can often be done on a pilot line at lower cost and with less time. Preliminary checkouts of base and chemical lots are often more efficient when run on a pilot line. By running these materials in a dynamic process, issues not seen in a lab test may surface. Today, many firms are producing low volume and high cost products that are much more economical when run on a narrow and slower line. A pilot machine is ideal for this purpose.

Many of the equipment manufacturers now have pilot lines so their potential customers can run their products and gain knowledge for the best design and specification. Primary issues are fluid application methods and drying.

Design of pilot lines range from very flexible, 6-in. wide customized units for under $400,000, to large 24-in. wide units with 20 ft of oven costing more than $1 million. They can be compact and enclosed with a small footprint or linear in design and two stories high. If the line is designed for a specific product and little future change is expected, compact units are very good.

However, in two years, one might need a number of new online devices (laminators, treaters, cleaners, preheaters), dryer changes, an alternate coating head, etc., where a more open and flexible layout would be a benefit.

Today's computerized data collection and analysis systems are well worth considering as part of the specification for a new pilot line. Signals such as web temperatures, fluid flow, coating weight and web tension are among the parameters often recorded. Today's instrument technology and computer modeling make it possible to significantly improve the ability for transition from pilot to manufacturing with little effort.

Support facilities must be considered. If the volume and product mix are high, fluid mixing and laboratory facilities must be close at hand. Having the pilot line located in the same facility as the manufacturing line can save costs.

Another question often raised is, who runs the machine? One or two dedicated operators are probably the best option as they learn the intricacies of the unit with experience.

Suppose you want to run pilot trials but don't want to invest in a pilot coating line. Options include buying time at a consulting research facility, equipment vendor or contract coating house.

Trial costs range from $1,000 to $18,000/day with many different levels of support. There are, however, some possible issues with this option. Among them are loss of security for sensitive products, lack of control of trial scheduling, and issues of travel and shipment of material.

E. Lawrence Gogolin, Gogolin & Associates, 978-779-9845, FAX 978-779-9845, Lgogolin@aol.com