Corona Treater Output vs.

Increase in
Dyne Level
Question: Can you offer any general guidelines on the relationship
between corona treater power output and dyne level increase?

Answer: The most basic measurement used to address this question

is called watt density (Wd). It is measured in kW per ft2 (or m2) per
minute. The equation is

(1) Wd = PS/(EW x LS x NST),

where Wd = Watt density; PS = power supply output in kilowatts;

EW = electrode width in feet or meters; LS = line speed in feet or
meters per second; and NST = number of sides treated.

Other things equal, higher watt densities result in greater increases

in the substrates surface energy (dyne level). However, the
relationship is neither linear nor simple watt density alone cannot
predict dyne level. A myriad of other factors will have an impact on
results.

The type of plastic (of the outer layer on coextruded or coated films)
is probably the single most important consideration. Whereas some
materials, such as polyester, accept treatment readily, others are less
susceptible. For example, polyethylene tends to be moderately
treatable, whereas polypropylene will require a considerably higher
watt density to achieve the same improvement in surface energy.

Film gage will likely have an effect, especially if the substrate

includes slip agents, anti-stat additives, or other constituents which
tend to bloom to the surface during and after corona treatment.
These all tend to decrease the effectiveness of the treatment,
especially over time. Film age especially if it was treated at
extrusion will therefore obviously also have an effect. Films which
were corona treated when extruded (a very good practice, as polymer
surfaces are more easily modified at higher temperatures, and prior
to setting their molecular structure), and being re-treated (bump-
treated) in line for printing, coating, laminating, etc., have a
stronger dyne level increase at a given watt density than will films
that have not been pre-treated.

During the primary treatment, at extrusion, there will be differences

in efficacy between cast and blown films, as well as between films
that are oriented or biaxially stretched vs. those that forego these
processes. These variations are due to molecular structure and
orientation, film temperature, and the proximity of the treater to the
extrusion die closer is better! For example, with cast film, the
treatment may be on the cold side, which has been exposed directly
to the chiller roll, or on the the hot side. The quench gap and quench
tank temperature will have an effect, as both these factors influence
molecular structure.

When treating a single side of a film, keep in mind that any back
treatment will sap energy from the treater, resulting in a lower dyne
level per Wd relationship. Along with back treatments potential to
cause blocking, this is a good reason to routinely test for this
unwanted phenomenon.

Finally, electrode type and gap, humidity, and possibly other effects
such as static buildup downline from the treater and the films
exposure to idler rolls may also have an effect on the relationship
between dyne level increase and watt density applied to the surface.

Under any set of conditions, expect the relationship to be non-linear;

the shape of the curve relating the two variables will be based on a
combination of all factors discussed above.

Having put all these caveats on the table, we can still draw some very
general conclusions as to appropriate watt densities for various
processes, as follows:

For treatment at extrusion with cast PE film, treat at Wd 2.0

kW/ft2/min cold side; 1.8 kW/ft2/min warm side (no orientation);
2.2 kW/ft2/min for oriented film. With blown PE film, treat at Wd 1.6
kW/ft2/min at top of tower; 2.0 kW/ft2/min halfway down tower; 2.0
kW/ft2/min at winder.(1)

For coating and laminating pre-treated PE film, bump treat at

Wd 1.2 1.4 kW/ft2/min for solvent coatings; 1.3 3.3 kW/ft2/min
for water based adhesives; 2.0 3.0 kW/ft2/min for UV coatings;
1.0 1.5 kW/ft2/min for 100% solids adhesives. (2)

The following data, from Enercon Industries, show typical

Wd values, in kW/ft2/min, for printing, coating, and laminating, as
well as suggested watt densities to achieve appropriate dyne levels
for several materials.(3)

Typical Watt Densities for Printing, Coating, Laminating

Solvent Water UV Solventless

Pretreated LDPE 1.5 2.0 2.0 2.5 2.0 2.5 1.0 1.3

Pretreated LLDPE 1.5 2.0 2.0 2.5 2.0 2.5 1.0 1.3

PET 1.0 1.5 1.0 1.5 1.0 1.5 1.0 1.3

Pretreated BOPP 2.0 2.5 2.5 3.0 2.5 3.0 1.0 1.3

Note: Variations in resin blend, additives or process will affect values.

Typical Treat Levels & Watt Densities

 Incoming Level Desired Level Watt Density

Treated BOPP 34 36 40 42 2.5 3.5

Treated BOPET 40 42 54 56 0.9 1.5

Treated LDPE, high slip 34 36 40 42 2.5 3.5

Cast PP, no slip 38 40 40 42 1.5 2.5

Untreated LDPE, low slip 30 31 no data no data

Note: Variations in resin blend, additives or process will affect values.

The following figure shows results published by Kasuga

Denki.(4) Note that one square meter = 10.75 square feet, so this
includes watt densities of as high as 11 kW/ft2/min for the 10% EVA.
This is an unusually high and probably in most cases unachievable
watt density, as most corona treating systems are sized for a
maximum Wd of 4.0 kW/ft2/min or less. The higher watt density
data points were probably produced at low line speeds.
References:

1) D.A. Markgraf, Determining the size of a corona treating

system, TAPPI J., 72, (Sep 1989), 173-178.

2) no author cited, Position of corona treating station, Faustel,

http://www.faustel.com/position-of-corona-treating-station/.

3) T.J. Gilbertson, Using watt density to predict dyne levels,

Enercon Industries,
http://www.enerconind.com/treating/library/technical-
articles/using-watt-density-to-predict-dyne-levels.aspx.

4) no author cited, Wettability (wetting tension) and watt density,

Kasuga Denki,
http://www.ekasuga.co.jp/en/product/185/00235.shtml.

Additional reading:

T.J. Gilbertson, Blame the corona treater the truth about watt
density, dyne levels, and adhesion, Converting Quarterly, 4,
(Quarter 2, 2014), 82-84.
no author cited, Corona treating watt density, Faustel,
http://www.faustel.com/corona-treating-watt-density/.

no author cited, Watt density: What is the formula to calculate watt

density?, Pillar Technologies, http://www.pillartech.com/Surface-
Treatment/Service-info/Troubleshooting-Guides/Watt-Density.