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Pilot Coating

Utilize our product expertise and custom coating capabilities to streamline the development of your adhesive coated products

Chemsultants International’s unique blend of new product development expertise and custom coating capabilities can streamline your development of web-coated products. We can help you to take products to market faster and improve existing product performance to meet critical market needs. Whether you need a coating you’ve developed applied to a unique film (toll coating), or an adhesive or topcoat applied to your substrate (custom coating), or some other combination thereof, you can rely on our capabilities and expertise to create the exclusive custom construction you require. We provide:

  • An expert staff of chemists and engineers to assist in product realization with adhesive selection, formulation development and rheological modification of adhesives and specialty coatings

  • Custom web coating expertise available utilizing various coating methods that optimize the production process

  • Staff with a proven record of attaining materials to meet the end product requirements

  • ISO 9001:2015 QMS highlights our commitment to providing product pilot  scale up, services for product prototyping and small volume roll to roll coating services in a clean and organized facility

  • Reduce, recycle, reuse or destroy? Ask us about the Regenerative Thermal Oxidizer (RTO) for solvent coatings. This unit attached to the coater exhaust destroys up to 99% of all volatile organic compounds (VOCs), hazardous air pollutants (HAPs) and odors through the process of high-temperature thermal oxidation

Utilize Chemsultants’ innovative product development and pilot coating services to develop or improve your products tailored to your end-use applications.

Chemsultants International’s largest coating line, the Universal Coater, has multiple coating capabilities and a Regenerative Thermal Oxidizer (RTO) for solvent coatings. This coater allows us flexibility to address the most challenging coating issues. With our full-service coating and process development facility, Chemsultants International has become a reliable contract manufacturer to many companies large and small.

Solvent & Emulsion Pilot Coating Line

Other services:  

  • Corona treating (offline up to 14” wide), laminating and delaminating

  • Regenerative Thermal Oxidizer (RTO)

  • Solvent or emulsion coating rheology analysis 


  • Coating substrate widths from 4 - 24” wide

  • Substrates – release liners, paper, film, foil and synthetics

  • Coating Methods – Knife-over-roll, direct and reverse gravure, offset gravure, meyer rod

  • Drying – three zone (individual zone controls), 30’ long air flotation ovens, max temperature of 400°F or the softening point of your substrate

  • Air flotation dryers use airbars to float the web through the dryer without making any contact. This dual sided air flotation system allows drying to be accomplished at lower air temperatures and with shorter dryer times

  • Line Speeds – 5 - 95 fpm

  • White room environment

  • Thickness tolerances ± 10% depending on coating method and raw material characteristics

Pilot Coating

Regenerative Thermal Oxidizer (RTO)

The regenerative thermal oxidizer (RTO) is used for the treatment of exhaust air that uses a bed of ceramic material to absorb heat from the exhaust gas. It then uses this captured heat to preheat the incoming process gas stream and destroy air pollutants emitted from process exhaust streams at temperatures ranging from      815 °C (1,500 F) to 980 °C (1,800 F). The RTO destroys air toxins, odors, VOCs, and hazardous air pollutants that are discharged in industrial process exhausts.

We care about solving problems without creating new ones. Our RTO enables us to work safely with solvents so you don't have to.

tape testing label testing
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