Coating Thickness Estimates

  • UV/EB Laminating Adhesive - Film-to-Film: 0.06 to 0.1 mil
  • UV/EB Laminating Adhesive - Film-to-Paper: 0.1 to 0.15 mil
  • UV/EB Flexo or Roller Applied Topcoat: 0.15 to 0.20 mil
  • UV Screen Topcoat: 0.20 to 0.30 mil
  • UV Ink Train or Letter Press Topcoat: 0.07 to 0.15 mil
  • UV PSA: 0.5 to 1.0 mil

Estimated Coating Cost Formulas (use chart below for mils)

Estimated Cost in $ per MSI
Thickness in Mils:
Price in $ per pound:
Estimated Cost in $ per MSF
Thickness in Mils:
Price in $ per pound:

Estimated Coating Usage Formulas (use chart below for mils)

Usage in Pounds (appx.) For Parts
Thickness in Mils (see chart below):
Part area in sq. inches:
Number of parts:
Usage in Pounds (appx.) By Web Width
Thickness in Mils (see chart below):
Web width in inches:
Length of run in feet:
Usage in Gallons For Parts
Thickness in Mils (see chart below):
Part area in sq. inches:
Number of parts:
Usage in Gallons By Web Width
Thickness in Mils (see chart below):
Web width in inches:
Length of run in feet:


Coating Thickness and Usage

(Assumes 9.0 lbs/gallon and 100% Solids Systems)

*Approximate only: depends on transfer efficiency, coating rheology, and other equipment setup factors

Application Recommendation* Thickness Coat Weight (weight/area)
Flexo   Screen Mesh mils microns lbs/1000 in2 lbs/1000 ft2 lbs/3000 ft2 grm/meter2
line count (lpi) cell vol (BCM) (plain weave)     (lbs/MSI) (lbs/MSF) (lbs/ream) (gsm)
400 - 600H 2 - 4 0.05 1.27 0.0019 0.28 0.84 1.37
200 - 400H 4 - 8 0.1 2.54 0.0039 0.56 1.68 2.74
120 - 200H 8 - 15 0.15 3.81 0.0054 0.84 2.52 4.11
100Q - 120H 15 - 25 450 - 500 0.2 5.08 0.0078 1.12 3.37 5.48
85 - 100Q 25 - 35 400 - 450 0.25 6.35 0.0097 1.4 4.21 6.85
65 - 85Q 35 - 40 350 - 400 0.3 7.62 0.0117 1.68 5.05 8.22
50 - 65Q 40 - 45 300 - 350 0.35 8.89 0.0136 1.96 5.89 9.59
45 - 50Q 45 - 50 250 - 300 0.4 10.2 0.0156 2.24 6.73 11
60 - 70T 50 - 55 220 - 270 0.45 11.4 0.0175 2.52 7.57 12.3
50 - 60T 55 - 60 200 - 250 0.5 12.7 0.0194 2.81 8.42 13.7
40 - 60T 60 - 70 180 - 230 0.6 15.2 0.0234 3.37 10.1 16.4
40 - 60T > 70 160 - 210 0.7 17.9 0.0273 3.93 11.8 19.2
40 - 60T > 70 140 - 190 0.8 20.3 0.0312 4.49 13.5 21.9
40 - 60T > 70 120 - 170 0.9 22.9 0.0351 5.05 15.1 24.7
40 - 60T > 70 100 - 150 1 25.4 0.039 5.61 16.8 27.4
Coverage
MSI/lb MSI/gal ft2/lb ft2/gal
513 4620 3560 32000
257 2310 1780 16000
171 1540 1190 10700
128 1150 893 8040
103 927 714 6430
85.5 770 595 5360
73.3 660 510 4590
64.2 578 446 4010
57 513 397 3570
51.3 462 356 3200
42.8 385 297 2670
36.7 330 254 2290
32.1 289 223 2010
28.5 257 198 1780
25.7 231 178 1600

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