Vinyl-Clad Manufacturing
Vinyl coated metal is a value-added product in which vinyl film is bonded to the surface of a metal sheet (usually Cold Rolled, Galvanized or Aluminum). Here's the "abridged version" of Clad-Rex's manufacturing process ...
Step 1. Cleaning
Steel or aluminum sheets per customer specifications (thickness, grade, physical/chemical properties, etc.) are cleaned, brushed and dried to prepare their surfaces for coating in the following manner ...
Stage 1. rinsed with hot water to remove surface impurities, dirt and oil
Stage 2. brushed to prepare sheet surfaces for cleaning
Stage 3. cleaned in a heated alkaline solution
Stage 4. rinsed twice using hot water
Stage 5. pretreated to improve adhesion
Stage 6. dried in-line
Stage 7. sheets are stacked on skids, then transferred to the laminating line
Step 2. Laminating
The "prepped" sheets then undergo the following process ...
Stage 1. fed onto the entry conveyor of the laminating line
Stage 2. enter a coating room where the appropriate adhesive is applied to the sheet
Stage 3. travel through a 100-foot long oven section to cure adhesive for lamination
Stage 4. exit the oven and immediately enter a set of laminating rolls where the
specified film and metal substrate are laminated together
Stage 5. the vinyl is trimmed to the sheets' edges (sides and ends)
Stage 6. the vinyl-clad sheet is cold water quenched, strengthening the vinyl adhesion and improving surface uniformity.
Step 3. Backside Painting
When orders specify paint on the backsides (for improved corrosion resistance), the sheets are carefully turned over so that the original (bare) bottom sides are now facing up. The sheets then travel through a coating head which applies paint to the back (non-vinyl) sides of the sheets, and then pass down a conveyor for drying. The vinyl-clad sides are carefully protected to guard against any paint spillover.
Step 4. Vinyl adhesion quality testing
The first and last sheets of every order are tested for vinyl adhesion. Depending upon order size, coating type, further QC protocols and other factors, more samples may be taken. They are tested and evaluated for adhesion, color and grain retention according to Vinyl Laminators Institute guidelines (CS-245-62).
Step 5. Shearing/Blanking
The vinyl-clad sheets are moved to our shearing department. They are cut to exact customer sizes and specifications, including width, length, and diagonal tolerances. During this process, the sheets and blanks are continually monitored for proper surface quality, flatness and dimension.
Step 6. Packaging
Material is evenly and tightly stacked, fully wrapped in strong waterproof packaging paper, and tightly banded to custom-fit wooden skids. Bar coded shipping tags are attached, clearly showing customer name, PO number, part name/number, finish type/color, thickness, size, quantity, weight, etc.
Step 7. Shipping
The packaged skids are carefully transferred to our shipping bays, ready for prompt shipment or customer pickup.
