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Valco Melton is a global provider of adhesive dispensing and quality assurance systems, with locations in more than 80 countries worldwide. For label manufacturers, we cover the full coating process, from melting and dosing to silicone coating and hot melt adhesive application through in-line quality inspection, integrating each stage into a single platform. This end-to-end capability gives converters tighter control over coating quality, less waste, and a single point of accountability across the line.

Silicone Coating

Valco Melton’s 5-roll silicone coating stations are designed increase uptime and work with UV free radical silicones across a range of substrates, from glassine and SCK papers to BOPP, PE, and PET films. Each roll is independently servo-driven, providing variable speed control and precise synchronization throughout the coating process. This independent drive technology delivers superior coat weight control, uniform application, and elimination of pinholes or coating defects.

The 5-roll configuration uses a progressive metering design: the first roll sets the base silicone dosage using precise gap control, while subsequent rolls gradually reduce coating thickness through a combination of pressure and speed differentials, producing consistent ultra-thin silicone layers with minimal waste. Quick-Swap Sleeve Technology integrates silicone patterns into interchangeable roll sleeves, enabling fast changeovers between jobs and flexible format changes without extended downtime. Operators can also quickly access the space between rolls for cleaning, maintenance, and sleeve replacements.

The UV curing chamber incorporates 2 UV mercury lamps, a large chill roll for substrate cooling, a slide-out quartz window with inert gas injection system, and measures parts per million of oxygen rather than a percentage.

Linerless

Valco Melton’s linerless coating line integrates silicone coating, UV curing, hot melt adhesive application, and quality inspection into a single platform. Eliminating backing paper entirely means no liner waste and no incineration requirement, reducing CO2 footprint and producing a cleaner production environment. Roll capacity increases by 30–40%, reducing roll changes and lowering transport and logistics costs. Using a single substrate to produce any label type also removes the need to stock multiple materials.

Beyond sustainability, linerless enables label configuration flexibility: printing on one or both sides, pre-printing with logos or watermarks, printing different label lengths without changing the roll, and custom adhesive configurations including different adhesive types, weights, and strip positions.

Line accessories and upgrades include Inspekt vision inspection systems, UV lamps, corona treatment, automatic splice turret rewinder, automatic butt splicer unwinder, slitting unit, turret rewinder with 4 shafts and automatic cycle change, flexographic printing groups, die-cutting unit, and automatic core hopper and loader system.

Linerless and Labelstock Coating Line

The linerless and labelstock coating line expands on the linerless platform by adding a second unwinder for laminating, enabling in-house production of specialty label constructions. The line is available in multiple configurations with web widths ranging from 150mm to 670mm depending on model. Mechanical speed reaches 200 m/min, web thickness ranges from 40 to 250 gsm, silicone coating weight runs 0.5–2.5 gsm via the 5-roll system, and adhesive coating weight ranges from 10–45 gsm with a rotating bar or 20–200 gsm via slot die.

This configuration supports specialty labels including those with adhesive applied over the printed side, multilayer formats such as piggyback labels and extended content labels, and pattern adhesive coatings including stripe, square, window-frame, and dual adhesive.

The two core benefit of this system are how it allows converters to start manufacturing new high-value label configurations in a cost-efficient way, even with short print runs, without outsourcing or holding inventory of multiple pre-coated stock alternatives. It also reduces purchasing costs: for applications that require a specialty adhesive or format, purchasing raw materials and coating in-house is more cost-efficient than sourcing pre-coated alternatives. The line also provides the ability to work with last-minute orders and to optimize stock by producing different products from the same substrate with different adhesive grades or add-ons.

Akura Pattern Roll Coater

For applications that require a specific adhesive pattern, Valco Melton’s Akura Pattern Roll Coater delivers consistent, clean results without limitations on pattern configuration. The system is compatible with hot melt PSA and UV curable adhesives, operates at speeds up to 100 m/min, and handles coating weights from ~.00025 to .004 mils.

Each roll in the station is independently motorized, allowing precise speed control for uniform adhesive distribution. Sleeve Pattern Technology enables fast job changeovers. Precision temperature control is continuously monitored and regulated to maintain optimal coating conditions. Key operational advantages include no minimum gap or coating threshold, no adhesive stringing, and no recurring spare part costs or module wear.

Akura Coating Station

For converters wanting to add hot melt coating capability to an existing press, the Akura Coating Station can be installed as a permanent fixture or a fully mobile wheel-in cart, handling continuous applications up to 660mm wide. Two applicator options, Akura PF with independent hydraulic zones and Akura M with single or multi-stream gear pumps, support a range of coating applications and machine speeds. A quick-change nozzle fastening mechanism allows simple transitions between continuous, intermittent, and rotating bar nozzle types.

Inspekt Quality Inspection

Quality control across all coating lines is supported by Valco Melton’s Lumitio brand inspection systems. Weight Inspekt is an in-line infrared grammage control system that measures coating weight independently of substrate thickness, and when paired with Akura Series hot melt applicators, operates in closed loop, automatically adjusting grammage deviations through direct communication with the dosing gear pumps. Coat Inspekt is a vision inspection system providing real-time defect detection with AI-based defect categorization, comprehensive roll defect mapping, and connectivity with downstream slitting stations to communicate defect locations and support rework planning. Together, the two systems provide complete product traceability from raw materials through finished roll.

With direct offices and authorized distributors across more than 80 countries worldwide, Valco Melton supports label manufacturers at every stage, from initial line configuration through ongoing production. More information is available at valcomelton.com.

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