Coatings Calculators and Estimators

The below calculators can be used as a reliable resource for the estimation for Waterbase and UV/EB coating consumption. These calculators are based on industry standard formulas for calculating coating consumption, however, variances in the coating application process due to mechanical and/or operational settings can alter the actual results for coating usage.

• Waterbase Coating

  Waterbase Coating Usage Estimator

  This calculator is designed to aid in the estimation of waterbase coating consumption in flexo applications based upon the criteria of coating area of coverage, anilox roller volume in BCM, and number of impressions.

  Substrate Length (in Inches)

  Substrate Width (in Inches)

  Number of Impressions

  Coating Area (in Percent)

  Anilox Volume in BCM*** (enter "10" for non-anilox systems)

  Calculate

  Estimated Waterbase Coating Required** (Lbs.)

  Estimated Waterbase Coating Required (Gal.)

  ** CAC recommended application rate is 1.0 wet lb. per 1,000 ft² for Waterbase coatings. For Heat-Seal/Blister-Pack coatings, CAC recommends an increased application rate of 1.5 wet lb per 1,000 ft²; Multiply this value by 1.5 for these applications.

  *** Actual wet application rate can vary depending on mechanical and operational settings of the coating unit, anilox condition/cell geometry, coating blanket material and coating viscosity.

• Waterbase Coating (metric)

  Waterbase Coating Usage Estimator - Metric

  This calculator is designed to aid in the estimation of waterbase coating consumption in flexo applications based upon the criteria of coating area of coverage, anilox roller volume in cm³/m², and number of impressions.

  Substrate Length (in cm)

  Substrate Width (in cm)

  Number of Impressions

  Coating Area (in Percent)

  Anilox Volume in cm³/m²*** (enter "15" for non-anilox systems)

  Calculate

  Estimated Waterbase Coating Required (kg.)

  *** Actual wet application rate can vary depending on mechanical and operational settings of the coating unit, anilox condition/cell geometry, coating blanket material and coating viscosity.

• UV & EB Coating

  UV/EB Coating Usage Estimator

  This calculator is designed to aid in the estimation of UV/EB coating consumption in flexo applications based upon the criteria of coating area of coverage, anilox roller volume in BCM, and number of impressions.

  Substrate Length (in Inches)

  Substrate Width (in Inches)

  Number of Impressions

  Coating Area (in Percent)

  Anilox Volume in BCM*** (enter "14" for non-anilox systems)

  Calculate

  Estimated UV/EB Coating Required (Lbs.)

  Estimated UV/EB Coating Required (Gal.)

  *** Actual wet application rate can vary depending on mechanical and operational settings of the coating unit, anilox cell geometry, coating blanket material and coating viscosity.

• UV & EB Coating (metric)

  UV/EB Coating Usage Estimator - Metric

  This calculator is designed to aid in the estimation of UV/EB coating consumption in flexo applications based upon the criteria of coating area of coverage, anilox roller volume in cm³/m², and number of impressions.

  Substrate Length (in cm)

  Substrate Width (in cm)

  Number of Impressions

  Coating Area (in Percent)

  Anilox Volume in cm³/m²*** (enter "22" for non-anilox systems)

  Calculate

  Estimated UV/EB Coating Required (kg)

  *** Actual wet application rate can vary depending on mechanical and operational settings of the coating unit, anilox cell geometry, coating blanket material and coating viscosity.

• UV & EB Screen Coating

  UV Coating Usage Estimator - Screen

  This calculator is designed to aid in the estimation of UV coating consumption in screen applications based upon the criteria of coating area of coverage, screen mesh ruling, and number of impressions.

  Substrate Length (in Inches)

  Substrate Width (in Inches)

  Number of Impressions

  Coating Area (in Percent)

  Screen Mesh (in LPI)

  Calculate

  Estimated UV Coating Required (Lbs.)
• Special Effect Varnish Coating

  Special Effect Varnish Usage Estimator

  This calculator is designed to aid in the estimation of roller-train special effect varnish consumption based upon the criteria of varnish area of coverage, paper absorbency, and number of impressions.

  Substrate Length (in Inches)

  Substrate Width (in Inches)

  Number of Impressions

  Varnish Area (in Percent)

  Paper***

  Calculate

  Estimated Varnish Required (Lbs.)

  *** Paper absorbency and hold-out will effect the varnish application rate to achieve the desired varnish/coating effect.

  Use the following values to calculate required varnish application rate based upon paper type:
  Non-absorbent/Plastic = 0.8
  Gloss Coated, good hold-out = 1.0
  Gloss Coated, poor hold-out = 1.1
  Dull/Matte Coated = 1.2

• Foil Method Coat-Weight

  Foil Method Dry Coat-Weight Calculator

  This calculator is designed to aid in the determination of achieved dry coat-weight for waterbase and UV coating products. An analytical balance calibrated to 0.0001 g is required. Results are calculated by inputing foil sample dimensions and measured foil sample weight, with and without dry coating film.

  Foil Sample Length (in Inches)

  Foil Sample Width (in Inches)

  Coated Sample Weight (in Grams)

  Uncoated Sample Weight (in Grams)

  Calculate

  Applied Dry Coat-Weight (lbs/1000 ft²)

  Applied Dry Coat-Weight (lb/ 3000 ft²)

  Waterbase coating recommended dry coat-weight:

  Coating Solids (in Percent)

  Recommended (lb/1000 ft²)

  Recommended (lb/3000 ft²)

  Difference Actual vs Recommended
• Applied Coat-Weight

  Applied Coat-Weight Calculator - Anilox

  This calculator is designed to aid in the estimation of applied wet and dry/cured coat-weight of waterbase and UV/EB coatings based upon anilox volume, anilox transfer efficiency and coating solids content.

  Anilox Roll Volume (in BCM)

  Transfer Efficiency (in Percent)

  Coating Solids (in Percent)

  Coating Density*** (in lbs/gallon)

  Calculate

  Applied Wet Coat-Weight (lb/1000 ft²)

  Applied Dry Coat-Weight (lb/1000 ft²)

  Applied Dry Coat-Weight (lb/3000 ft²)

  *** Recommended coating density for waterbase coating is 8.8 lbs/gallon. Recommended coating density for UV/EB coating is 9.1 lbs/gallon.

  *** Transfer efficiency of the anilox can vary based upon anilox condition, cell geometry and coating viscosity. 25% is a typical transfer percentage for use with anilox rolls that are in good condition in regards to wear and contamination.