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Introduction

Kerone’s Knife-Over-Roll Coating Machines are engineered for high-viscosity formulations and applications that demand thick, uniform coating layers. Using a fixed blade positioned over a rotating roll, this system provides precise deposition control and is widely used in industries requiring durable, functional, and high-weight coatings.

It has traditionally been the choice when needing to put down a substantial and level coating of medium to high consistency onto uneven surfaces, for example, materials, fiber glass mats and non woven. Average applications incorporate cast movies, emblazoned and plain deck, fortified plastics, medicinal dressings, material cement coatings

This process depends on a coating being connected to the substrate which then goes through a “gap” between a “knife” and a bolster roller. Contingent upon the wanted impact to the knife is countered by a roller, platen or nothing by any means; in this manner roller knives, platen knives and air knives are recognized. The knife bar of current coating plant is outfitted with a few coating knives and is alterable as per the pistol rule. This encourages a brisk change of the knives, particularly of the roller and the air knife.

Now and again, the sides scrubbers are finished to a shut glue bowl with a front plate, which is fundamental particularly when low-thick coating glues are concerned. Contingent upon the thickness of the cover to be connected, in transit of the knife’s design and the consistency of the glue, knives of diverse profiles are utilized.

Why Choose Kerone Knife-Over-Roll Coating Machine

Kerone integrates precision-ground knife assemblies, stable roll geometry, and advanced tension control systems to ensure smooth and predictable coating behaviour. Each machine is fully customizable—allowing fine adjustment of blade angles, coating gaps, line pressure, roll temperature, and web handling to match specific coating chemistries and material properties. This results in consistent, high-quality coatings even at challenging thickness levels.
We are having immense experience in designing and manufacturing of Knife Over Roll coating machine that can best fit for the size and various processing requirements of the client’s business. The Knife Over Roll coating machines manufactured by KERONE are made with high quality internal and external material by taking discreet efforts for the perfect coat and uniform heat distribution.

Types and Features of Knife-Over-Roll Coating Machine

Kerone’s Knife-Over-Roll Coating Machines are available in customizable configurations featuring adjustable knife assemblies, heated or cooled rolls for viscosity control, pre-metering trays for consistent material feed, and high-efficiency drying sections designed for rapid curing. The system supports manual or motorized knife gap adjustments, precise blade angle control, and stable roll geometry to ensure consistent and uniform coating thickness. With robust drive mechanisms, advanced tension control, and modular design options, these coaters offer flexible integration and reliable performance across a wide range of high-viscosity coating applications.

Key Features

  • Excellent for high-viscosity & high-deposition coatings
  • Adjustable knife gap for precise and repeatable thickness control
  • Suitable for thick coatings with consistent weight distribution
  • Smooth, uniform coating on films, textiles, papers, and laminates
  • Automated tension control for stable web movement
  • Energy-efficient drying, curing, and thermal management systems
  • Compatible with pastes, resins, adhesives, polymers, sealants & rubber-based coatings
  • Rugged, durable construction for long-term continuous operation

Powered by AI, ML & IoT

Future-Ready Engineering Driven by AI & IoT

Our advanced AI, ML, and IoT technologies, this solution delivers smarter automation, real-time insights, and predictive intelligence to enhance efficiency and drive future-ready growth.

Real-Time Monitoring & Control

Continuous tracking of process parameters with instant adjustments.

Predictive Maintenance

Intelligent fault detection to prevent failures before they occur.

Adaptive Process Optimization

Dynamic tuning of operations for maximum output and efficiency.

Cloud Dashboards & Analytics

Unified access to real-time insights and performance trends.

Energy & Resource Savings

Smarter utilization of energy to cut costs and reduce waste.

Secure IoT Connectivity

Encrypted data flow with seamless integration across plant systems.

Applications of Knife-Over-Roll Coating Machine

Kerone Knife-Over-Roll Coating Machines are suitable for:
    • Thick adhesive and paste coatings for industrial use
    • Functional coatings on films, foils, and specialty substrates
    • PVC, rubber, and polymer layer deposition
    • Protective and construction-grade laminates
    • Textile coatings requiring high deposition weight
Kerone’s Knife-Over-Roll Coating Machines deliver precise, thick, and uniform coatings for high-viscosity materials. With customizable knife settings and advanced drying options, they provide reliable performance across diverse industrial applications.

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Frequently Asked Questions (FAQ)

  • The fixed knife blade provides direct metering control, allowing thick, high-viscosity formulations to spread uniformly without relying on roller cell patterns or low-viscosity flow.
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