Tape Film Coating Inspection: CTS 3.0 Dual-Inspection Technology Reduces Hidden Production Losses

Have manufacturers of adhesive tapes and functional films long been burdened with various production losses that are difficult to quantify?

1. Excessive coating thickness leads to a continuous increase in adhesive material consumption, driving up overall production costs.
2. Insufficient coating thickness results in substandard adhesion of finished products, triggering customer returns and exchanges, and damaging brand reputation.
3. Minor surface defects that go undetected in time cause entire rolls to be scrapped, incurring substantial material losses.
4. Coating uniformity and surface appearance directly determine production costs, product reputation, and the stability of customer cooperation for adhesive tape and film manufacturers.

An industrywide pain point: a single inspection solution leaves blind spots in quality control.

Pain Point 1: Coating thickness fluctuations are difficult to monitor visually.

The surface of adhesive tapes and films is often covered with release paper or release film, making it impossible for traditional optical inspection to penetrate the top layer. Manufacturers are forced to rely on manual sampling and tactile judgment to assess coating conditions – data that offers little reference value.

Pain Point 2: Defects are easily missed on highspeed production lines.

Coating lines typically run at speeds of 100–300 m/min, while manual visual inspection has limited response time. As a result, tiny bubbles, scratches, impurities, and other defects are prone to being overlooked.

Pain Point 3: Production data lacks complete retention.

Without online realtime inspection records, when a customer quality complaint arises, there is no way to trace back to the corresponding production batch or process parameters. As a result, companies often have to bear the full cost of the loss themselves.

Chongqing Arise Technology Co., Ltd. (hereinafter referred to as “Arise”) has launched the CTS 3.0 Coating Quality Tracking System, which employs a combined solution of microwave radar and visual dualinspection to specifically address the production control challenges mentioned above.

DualInspection Core Functions – FullScale Coating Quality Control.

Microwave radar penetrating inspection for precise control of coating thickness.

1. Microwave radar penetrates release paper, release film, and printing ink layers, capturing dynamic changes in coating amount in real time.
2. It outputs areal density and coating weight data in real time.
3. When coating thickness deviates from the standard range, the system automatically triggers an alert, helping companies stabilize adhesive usage and reduce material waste.

Machine vision performs synchronized inspection, covering the full surface width of highspeed production lines.

1. The vision module scans the film surface in sync, identifying various surface defects such as bubbles, impurities, scratches, and uneven coating.
2. Radar and vision data are cross-verified, providing simultaneous alerts for coating irregularities and surface blemishes.
3. Compatible with highspeed production lines up to 300 m/min, it scans the full width with no blind spots, significantly reducing missed defect detection.

Fullprocess data storage enables batchlevel quality traceability.

1. Automatically stores coating parameters and surface imaging records for every roll of tape or film.
2. Generates visual data reports that can be retrieved and searched by production batch, time period, or machine unit.
3. When quality feedback is received from a customer, the complete production record of the corresponding roll can be quickly accessed, enabling efficient identification of the root cause.

A complete line solution tailored for tape and film production lines.

Tailored to the production requirements of adhesive tape and film manufacturing, Arise offers an integrated control module that operates in coordination with the CTS 3.0 system:

1. Web Guiding System: Optimized for adhesive tape coating processes, it stabilizes the edge coating position and prevents offsetrelated material waste.
2. Tension Control System: Designed to accommodate the easystretch characteristics of films, it maintains consistent tension across the entire line to avoid film deformation.
3. Register Control System: Ideal for printed adhesive tapes, it ensures color consistency across the entire production batch.