Dual-Zone Transfer Coating Machine XN-RTCA-500 – Three-Roll Continuous, Two Independent Drying Zones, 200–1500 mm/min, ±0.5 μm Accuracy, 10 kW | Xnergy

Name: Dual-Zone Transfer Coating Machine XN-RTCA-500

Equipment Type: Three-Roll Continuous Transfer Coating Machine with Two Independent Drying Zones & Recipe-Based PLC Control

Product Code: XN-RTCA-500

Product Introduction:

The Dual-Zone Transfer Coating Machine XN-RTCA-500 is an advanced three-roll transfer coating system equipped with independently controlled dual-temperature drying zones. The XN-RTCA-500 is specifically designed for high-performance coating processes requiring staged drying profiles, such as lithium-ion battery electrodes, supercapacitor electrodes, and other functional thin-film materials. By enabling independent temperature control in each drying zone, this system allows optimized solvent removal and film formation, significantly improving coating quality, adhesion, and process stability. As a result, the XN-RTCA-500 is an ideal solution for advanced research, pilot-scale development, and process scale-up studies.

Product Features:

• Dual drying zones with independent temperature control for optimized drying performance
• Modular drying chamber design with adjustable length per zone
• Continuous transfer coating with excellent coating uniformity and repeatability
• Upper and lower hot-air circulation drying enhances solvent evaporation efficiency
• Precision tension control system ensures stable substrate transport
• Three-roll transfer coating structure delivers smooth surface finish and accurate thickness control
• PLC control with touchscreen interface enables easy parameter setting and recipe management
• Optional solvent recovery system available to support environmentally compliant operation

Main Specifications:

Values measured by Xnergy. Typical values for reference; not guaranteed unless otherwise specified.

Application Areas:

• Lithium-ion battery electrode coating — staged drying profiles for advanced electrode formulations
• Supercapacitor electrode coating — uniform coating with controlled drying for supercapacitor research
• Other functional thin-film materials requiring two-zone independent temperature control
• Advanced research where staged drying profiles improve coating quality, adhesion, and process stability
• Pilot-scale development and process scale-up studies
• Coating processes where independent temperature control in each drying zone enables optimized solvent removal and film formation

Recommended Operating Procedure:

1. Power on the XN-RTCA-500 and verify that the PLC + touchscreen HMI, three-roll coating station, dual independent drying zones, hot-air circulation system, tension control, and unwind/rewind drives are all operating normally. 2. Connect the compressed air supply (0.5–0.7 MPa) to the equipment air inlet. 3. Mount the substrate roll on the unwinding shaft and thread the substrate through the three-roll coating station, the two independent drying zones (1 m per zone, customizable length), and onto the rewinding shaft (max. Φ250 mm). 4. Configure the tension control setpoint on the touchscreen HMI (within the max. 60 N adjustable range) for stable substrate transport. 5. Set the target coating gap on the touchscreen HMI to achieve the desired wet film thickness (typical range 40–300 μm) with thickness accuracy ±0.5 μm and coating uniformity ±1 μm. 6. Set the target coating speed (within 200–1500 mm/min). 7. Set the target temperature for each drying zone independently on the touchscreen HMI (within ambient–150 °C) to define the optimized staged drying profile for the slurry chemistry being coated. 8. Save the configured drying profile as a recipe via the touchscreen HMI for future reproducibility. 9. Allow the drying zones to reach setpoints and stabilize. 10. Load the coating slurry, then initiate the run; the substrate advances continuously through the three-roll transfer coating station and the two independent drying zones, with finished material rewound on the rewinding shaft. 11. Monitor coating thickness, uniformity, and tension during the run; adjust parameters as needed via the touchscreen HMI. 12. After the run, allow the heating zones to cool, then remove the rewound roll. Clean all wetted surfaces with appropriate solvent (water or NMP, depending on the slurry system used) and dry thoroughly before the next run.

Optional Solvent Recovery System:

The XN-RTCA-500 supports an optional solvent recovery and treatment module for environmentally compliant operation. The solvent recovery module captures and processes evaporated solvent (such as NMP) from the drying-zone exhaust, reducing solvent emissions and supporting compliance with local environmental regulations on VOC discharge. Contact our team for solvent recovery configuration options matched to your specific slurry chemistry and recovery throughput requirements.

Packaging & Storage:

The XN-RTCA-500 ships fully assembled with the three-roll transfer coating station, two independent drying zones with modular adjustable-length chambers (1 m per zone), upper and lower hot-air circulation system, tension control system, unwind and rewind drives (max. Φ250 mm), PLC + touchscreen HMI control panel with recipe management, and modular frame (~L2900 × W1030 × H1380 mm). Optional solvent recovery and treatment module ships separately if ordered. Install on a stable laboratory or pilot-scale floor in a clean, dry environment, away from heat sources, direct sunlight, and corrosive atmospheres. Connect the equipment to a compressed air supply (0.5–0.7 MPa) and to a power supply matching local electrical standards (10 kW maximum power consumption). Disconnect the power supply when the equipment is not in active use. After each use, clean all wetted-surface components, dry thoroughly, and store the equipment in a clean, dry environment. Inspect the three-roll coating station, drying zones, tension control mechanism, unwind/rewind drives, and PLC system periodically for wear or contamination.

Safety:

For research and industrial use only. Always follow standard safety protocols when operating coating equipment with heated surfaces. Do not touch the heated drying zones, coated substrate, or hot-air ducts during operation — surface temperatures up to 150 °C can cause burns. Always wear appropriate PPE (safety glasses, chemical-resistant gloves, lab coat) when handling slurries, solvents, and coated electrodes. When working with NMP-based slurries or other regulated solvents, ensure adequate ventilation and exhaust extraction; consider pairing the XN-RTCA-500 with the optional solvent recovery and treatment module, and follow local regulations on solvent use, recovery, and emission. Disconnect the power supply and isolate the compressed air supply before any cleaning, maintenance, or component replacement. Allow all heating zones to cool to room temperature before any cleaning or sample-handling operations. Keep hands clear of the moving three-roll coating station, tension rollers, and unwind/rewind drives during operation. Refer to the included user manual for complete safety and operating instructions.

Note: Specifications listed above are typical and for reference only. Actual performance depends on the specific slurry chemistry, viscosity, coating thickness, drying temperature setpoints in each zone, drying length, substrate type, and ambient operating conditions — consult published literature and our technical team for guidance on specific dual-zone transfer coating-and-drying protocols. For researchers exploring complete lithium-ion battery electrode preparation workflows, see also Xnergy’s related products: Laboratory Transfer Coating Machine XN-RTCA-300 (smaller laboratory single-drying-zone version), Segmented Transfer Coating Machine XN-RTCA-300-3 (pilot-scale multi-zone version), Comma-Blade Continuous Coating Machine XN-KD200, Continuous Roll-to-Roll Coating Machine XN-LVC-200, Slot-Die Coating System XN-SDC, Slot-Die Extrusion Film Applicator XN-FAS-100, Extrusion Feeding Pump XN-EFP, Automatic Film Coater XN-VC-300, Glove-Box-Compatible Film Coating & Drying Machine XN-VCH-200, Automatic Film Coater with Integrated Drying System XN-VCH-300, Automatic Film Coating & Drying Machine Plus XN-VCH-800, Bottom-Heated Film Coating Machine XN-VCHB, Adjustable Film Applicator XN-FAT-100, Three-Stage NMP Processor XN-NMP-3, Planetary Vacuum Mixer for Mixing Electrode Powders, Three-Door Vacuum Drying Oven (XN-DVO-3), and the full Coating equipment category, Pilot-Scale Coating equipment category, Drying equipment category, Calendaring equipment category, Slitting & Die Cutting equipment category, and NMP Solvent Recovery equipment category. For complete electrode formulation systems, see also Cathode Materials, Anode Materials, Binders, and Current Collectors.