Solvent Coater Retrofit for Technical Training and Workforce Develop-ment

Client: New College Institute

Capabilities Demonstrated

Web handling and coating system retrofits
Mechanical and control system redesign
Modular training equipment development
Control panel build and HMI programming
Web handling training and workforce development support
Turnkey installation and commissioning

Challenge

A technical education institute in the southeastern U.S. sought to build a hands-on training facility to address a growing skills gap in advanced manufacturing. Local employers in the film and plastics industries were struggling to hire qualified technicians, especially for coating and web conveyance roles.

The institute needed a fully functional training machine that mirrored real-world processes, could support multiple concurrent classes, and operated within a limited budget. Purchasing a new coater was not financially feasible, and off-the-shelf solutions lacked the technical fidelity and instructional flexibility required.

Approach

Re:Build Optimation was brought in to develop a creative and cost-effective solution. Rather than building a machine from scratch, the team sourced a used solvent coater from the UK and retrofitted it to support aqueous coating and modular training needs.

Key elements of the approach included:

Sourcing and importing a solvent coater that met baseline mechanical criteria
Mechanically modifying the machine to include a web guider, wrinkle module, traction module, and web take-up system
Stripping and replacing legacy controls with a modern automation platform
Developing a user-friendly GUI that mirrored local film manufacturing systems
Designing modular training stations to allow multiple classes on different machine sections simultaneously
Integrating the control and air systems at ground level for ease of access and instructional use

Solution

The retrofitted system was fully rebuilt for aqueous coating and optimized for technical instruction. Automation upgrades included:

New Drives and Actuators: Installed modern motion components to improve reliability and teaching potential
Controls Architecture: ControlLogix PLCs, PowerFlex drives, and Wonderware HMI, with localized Rockwell PanelView Plus units for multi-point access
Teaching Modules: Added conveyance stations for web handling, maintenance, diagnostics, and drying process instruction
Data Logging: Enabled student performance tracking and system diagnostics during coursework

The system was fabricated and tested in Re:Build Optimation’s Rochester, NY facility, then disassembled, shipped, and installed on-site. Final wiring and commissioning were completed in collaboration with local resources.

Result

The retrofit project empowered the institute to deliver high-quality, hands-on training for local manufacturing roles. With continued use in educational programs and demand for additional system enhancements, the project stands as a model for budget-conscious, industry-aligned workforce development. Re:Build Optimation’s creativity and full-spectrum engineering support enabled the client to expand training capabilities while supporting local economic growth.

Benefits & Impact

Cost-Effective Execution: Delivered an advanced training system within a constrained budget
Hands-On Training: Enabled multi-station, real-world process instruction across coating and conveyance disciplines
Scalable Curriculum: Supports multiple concurrent classes and modular instruction
Real-World Relevance: Replicates equipment and control systems found in local industry
Future Enhancements: System continues to evolve, with new coating modules like slot die and solution delivery being added

System Overview

System Type: Retrofitted solvent coater for aqueous coating and modular training
Function: Provides hands-on instruction in coating, web handling, and process diagnostics
Key Features: Modular layout, Rockwell/PanelView controls, Wonderware HMI, data logging
Deployment: Technical training institute in southeastern U.S.
Industries Served: Film and plastics, technical education, industrial workforce development

Ready to Partner?

Let’s talk about your unique challenges and how Re:Build Optimation can help you.