Reach commercial scale faster with flexible, production-scale toll coating services.
Promising coatings rarely fail in the lab. They stall on the way to production. Teams often can’t get access to roll-to-roll equipment, can’t justify the capital to buy it, or don’t have the coating expertise in-house to run it. Re:Build’s toll coating services close that gap.
Our coating engineers and operators draw on more than 40 years of web handling expertise to help you develop, validate, and scale your process with fewer iterations. And because we design and build advanced roll-to-roll systems, we can reconfigure our line to support novel materials, demanding substrates, and challenging applications.
Prove your process under production conditions and reach commercial scale in fewer development cycles. We review your formulation against real coating and drying conditions, so the process we develop supports the formulation you’ll actually produce.
As machine builders, we are able to configure our coater around your material, adding in-line quality control, custom instrumentation, and alternative curing methods as needed, so the process you validate is the process you scale.
With proprietary predictive models, a database of 1,500+ webs, an in-house conveyance research lab, and specialized engineering experience, our team brings coating expertise you can’t find anywhere else.
Our roll-to-roll capabilities give manufacturers the control, consistency, and throughput needed to advance material performance and move from development to production more efficiently.
Run anything from short R&D trials to qualified, recurring production on equipment large enough to generate process-representative data.
We help you find and lock in the right coating method, process window, and drying conditions for your material. You reach a repeatable, production-ready process in fewer iterations.
Move from pilot to production with a clear scale-up plan, defined process parameters, and the capability metrics you need to qualify your product. When you outgrow our capacity, we can build your own line to the process you’ve proven.
Bring us a defect, a yield problem, or a process that isn’t scaling. Our coating and web handling engineers will help you find the root cause and fix it.
We build those, too. Re:Build brings decades of experience, a database of over 1,500 web materials, and proprietary predictive models to design and build custom roll-to-roll systems. Our services include:
| Coating Methods | Slot die, gravure, kiss coating, and other configurable methods |
| Coating Width | 12″-51″ |
| Max Web Width | 53″ |
| Line Speed | Process dependent, from approximately 20-500 ft/min |
| Substrates | Films, foils, papers, membranes, engineered webs |
| Max Roll Weight | 1,200 kg (2,645 lb) |
| Max Roll Diameter | 1,000 mm (39.4″) |
| Additional Capabilities | Lamination, mixing and blending coming soon |
Tell us about your project and our Coating Center of Excellence team will be in touch.
Re:Build Optimation’s Web Handling Fundamentals workshop provides hands-on training grounded in decades of real-world engineering experience. The program covers essential web handling principles such as tension control, traction, wrinkling, splicing, winding, and process stability to support reliable, high-performance roll-to-roll systems.
We offer custom tramming rods and hand-held alignment kits available for order online, specifically designed for roller alignment and web handling equipment setup. Whether you’re aligning rollers, calibrating web paths, or setting up new machinery, our tools deliver the accuracy, repeatability, and efficiency you need.
Download our free library of technical white papers developed by Re:Build Optimation’s engineering experts to gain practical insights backed by real-world testing and analysis. Topics include fluid-structure interaction in thin webs, web-to-roller traction measurement, splice performance modeling, and more.
