Dual-Zone Transfer Coating Machine XN-RTCA-500

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.

Main Features:

• Dual drying zones with independent temperature control — optimized drying performance for staged solvent removal
• Modular drying chamber design with adjustable length per zone — 1 m per zone standard, customizable
• Three-roll transfer coating structure — smooth surface finish and accurate thickness control
• Continuous transfer coating — excellent coating uniformity and repeatability
• Upper and lower hot-air circulation drying — enhances solvent evaporation efficiency
• Precision tension control system — stable substrate transport, max 60 N adjustable
• PLC control with touchscreen HMI — easy parameter setting and recipe management for reproducible runs
• High coating accuracy — ±0.5 μm thickness, ±1 μm uniformity
• Optional solvent recovery and treatment module — for environmentally compliant operation with NMP or other regulated solvents

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 (NCM, LFP, LCO, LMO, graphite, Si-C)
• Supercapacitor electrode coating — uniform coating with controlled drying for supercapacitor research
• Functional thin-film materials — applications 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 — transition from benchtop to production scale
• Sodium-ion battery and solid-state battery electrode coating with staged drying
• Functional membrane, ceramic film, and specialty thin-film research

Recommended Operating Procedure:

1. Install the XN-RTCA-500 on a stable laboratory or pilot-scale production floor in a clean, dry environment; connect the equipment to a compressed air supply (0.5–0.7 MPa) and to a power supply matching local electrical standards (10 kW max). 2. Power on the unit 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. 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.

Maintenance:

• Frequently wipe the machine with a soft cloth dampened with alcohol to keep it clean
• Lubricate moving parts with oil to keep movement smooth
• If the machine will not be used for an extended period, wipe down the surface of moving components and apply a protective rust-prevention oil
• Periodically inspect screws, nuts, pins, and other fasteners across all parts of the machine to prevent loosening
• Periodically clean the drying zone nozzles and inspect the chambers for residue buildup that could affect drying uniformity
• Periodically inspect the three-roll coating station for wear or contamination affecting coating thickness
• Periodically inspect the tension control system, unwind/rewind drives, and air-expanding shafts

Optional Solvent Recovery System:

The XN-RTCA-500 supports an optional solvent recovery and treatment module for environmentally compliant operation. The 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, ~1200 kg net). 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. Disconnect the power supply and isolate the compressed air 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.

Safety:

For research and industrial use only. During operation, do not insert hands or any other body parts into the three-roll coating station, rotating tension rollers, unwind/rewind drives, hot-air drying zones, or any other moving or hazardous working areas to prevent personal injury. Operation by two or more persons simultaneously is not allowed to avoid accidental injury. External (third-party) technical personnel and unauthorized persons must not disassemble the equipment under any circumstances. Do not touch the heated drying zones, coated substrate, or hot-air ducts during operation — surface temperatures up to 150 °C can cause severe burns. Always wear appropriate PPE (safety glasses, chemical-resistant gloves, lab coat, safety shoes) 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 — NMP and similar aprotic solvents have specific exposure limits under OSHA, EU REACH, and other regional safety frameworks. 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. 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. The XN-RTCA-500 is the dual-zone pilot-scale member of Xnergy’s transfer coating lineup; for the smaller single-drying-zone laboratory version, see the Laboratory Transfer Coating Machine XN-RTCA-300; for the pilot-scale multi-zone segmented version, see the Segmented Transfer Coating Machine XN-RTCA-300-3. For comma-blade continuous coating with single-zone drying, see the Comma-Blade Continuous Coating Machine XN-KD200. For compact roll-to-roll coating with infrared drying, see the Continuous Roll-to-Roll Coating Machine XN-LVC-200. For slot-die coating, see the Slot-Die Coating System XN-SDC, Slot-Die Extrusion Film Applicator XN-FAS-100, and Extrusion Feeding Pump XN-EFP. For benchtop film coating (non-roll-to-roll), see the Automatic Film Coater XN-VC-300, Automatic Film Coater XN-VC-800, 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, and Adjustable Film Applicator XN-FAT-100. For NMP solvent recovery and treatment, see the Three-Stage NMP Processor XN-NMP-3. For upstream slurry preparation and downstream drying, see the Planetary Vacuum Mixer for Mixing Electrode Powders and Three-Door Vacuum Drying Oven (XN-DVO-3). For downstream calendering, see the laboratory CRP / CRPE / CRPE-W / HRPE / HRPH series, the pilot-scale Hydraulic-Balance Motorized Roller Press XN-HPRP-300 & Heated Hydraulic-Balance Roller Press XN-SHPRP-300, and the Roll-to-Roll Continuous Hydraulic Calendering Machine XN-HRPER-300. For full equipment categories, see the Coating equipment category, Pilot-Scale Coating equipment category, Drying equipment category, Calendering equipment category, Pilot-Scale Calendering 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.