Mayer Bar Manufacturers | Mayer Bar Suppliers | Mayer Bar Distributors

What is the Mayer bar?

Mayer bar coating is executed by a stainless steel rod known as the Mayer rod, which is tightly wound with stainless steel wire of distinct diameter. The rod is designed in such a way that it controls the coating balance. Further, the wire that is used to wind the roll comprehensively determines the wet-thickness after coating.

The rods are available in numerous sizes that further provide plenty of options for coating weights. Different wire sizes offer different wet thickness, on the other hand, the dry thickness is determined by the concentration of solids present in the coating solutions.

Why Choose Mayer bar coating?

The battle of top coating methods has always been won by a Mayer bar coating due to a number of reasons. Likewise, it is the most simple yet efficient way to perform the coating with the maximum evenness and uniformity. The precision, smoothness, and cost-efficiency are the other major highlights of Mayer bar coating. In addition, this coating method fits well for every industry that needs to perform regular coating tasks, as it gives maximum results in the minimum span of time.

Also, the freedom of changing the coat weights makes it possible to achieve the thickness of choice. Above all, it works ideally with every coating and substrate available at the time. At TFT Industries, we offer a wide range of coater options with the aim of providing a befitting solution for most of the applications.

What are the advantages of Mayer bar:

The popularity of Mayer bar coating is rapidly growing because of the long-line of advantages one gets. Though it is a traditional way of coating, it is appealing to today’s generation the most due to the advancements like multi-wire designs and special wire surfaces. Besides, you get benefits like:

• 1. The perfection in coating with minimum efforts
• 2. Very predictable after-effects
• 3. Finest coating at minimal prices
• 4. Ease of operation
• 5. Very easy coat weight adjustments
• 6. A broad range of coaters
• 7. Freedom to tune the thickness with ease keeping the coating material constant
• 8. Less time-consuming technology
• 9. Very inexpensive changeovers
• 10. Works well with advanced equipment
• 11. Different wire sizes to control the web thickness
• 12. Compatibility with a wide range of coating substrates or solutions
• 13. Low repair-cost

Why us?

We offer bar coaters that can effectively apply paints, adhesives, printing inks, lacquers and other coatings on the surface like paper, board, metal plates, plastic film, foils, glass plates, wood, etc. Two or multiple coatings can be applied simultaneously with a single operation, that gives you an ideal system to perform the comparison.

Our experience and quality speak for us. We strive to attain the maximum customer-satisfaction hence offer the unmatched quality in our products and services. If you are looking for reasons to choose us, here are a few considerable points:

• ✓ Simple at cost-effective
• ✓ It can deposit from 4 to 500-micron wet film thickness.
• ✓ Great repeatability due to the special impression bed.
• ✓ The stainless steel rods for extended life
• ✓ Numbered and color-coded bars
• ✓ The concurrent coating or two or multiple products for clear comparison.
• ✓ Get plenty of bar coater options
• ✓ Best quote for evert size and diameter of bar coaters
• ✓ Numerous sets of specifications at the lowest prices

What Variety of Rod Types is available:

1. Wire Wound Rods

It is the original form of “Mayer rod” that is comprehensively available since 1920. It is presently available in #3 to #75 sizes and several half sizes. The size here represents the diameter of the wire in mils (.001 inch). These rods can be stripped and rewound and thus are economic and eco-friendly at the same time. The wire-wound rods are free from minimums and setup charges.

2. Formed Rods

Formed rods hold close resemblance to the wire wound rod. A Formed rod (threaded, grooved, or more) is a roll, formed from a solid steel bar. In this type of rod, the groove size delimits the thickness of the coating, just like the cavity between the wire winding does. Nevertheless, the formed rods are easier to clean as the radius in the groove rods clogs very seldom.

3. Smooth Rods:

The smoothed rods are used to smoothen the already metered coatings to paper, paperboard, and plastic films. The thickness of the coating is determined by the pressure against the back roller or the web tension. The smooth rods offered by us, are designed to meet the requirements of finishing for any surface and the hard chrome plating serves to the need for longevity or extended life of the rod.

4. Gapped Rods:

Gapped Rods are used for the coatings of high viscosity as the gap between rods controls clogging and remove lines for a smoother effect. The gapped rods are wound with a small wire with spacing, that creates a wide and shallow cavity to ensure the smooth flow of heavy coatings. The smaller wire causes a lesser interruption in the flow of coating and this enables the coating to wet out in a better manner. However, the gapped rod has lesser durability than that of the double wound rod but it is more cost-efficient.

5. Double Wound Rods:

Double Wound Rods very closely resemble the gapped rod. It is also meant to work with high viscosity coatings. It gives a smooth coverage because the smaller wire on the top of the larger wire creates a wide and shallow cavity that allows the heavier coatings to flow smoothly. The smaller top wire ensures less interruption in the gliding process and thus allowing the coating to wet out more effectively. Moreover, Double wound wires are more durable than the gapped rods but cost more.

Standard Mayer Bars:

Close Wound

Bar No.	Colour Code	Wire Diameter		Wet Film Deposit
		INS	MM	UM
0	White	0.004	0.10	4
1	Yellow	0.005	0.12	6
2	Red	0.006	0.15	12
3	Green	0.007	0.18	24
4	Black	0.010	0.25	40
5	Horn	0.016	0.40	50
6	Orange	0.020	0.50	60
7	Brown	0.030	0.75	80
8	Blue	0.040	1.00	100
9	Tan	0.048	1.20	120

Open Wound

Bar No.	Wire Diameter		Wet Film Deposit
	INS	MM	UM
150	0.060	1.52	150
200	0.080	2.00	200

Mayer Wire variety:

The customized bars to apply intermediate wet film deposits are designed as per the requirement of the customer. There are plenty of wire diameter options of the following deposits (microns) are available, for the close wound.

4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 76, 80, 84, 88, 90, 92, 96, 100, 104, 108, 110, 112, 116, 120, 128, 130, 140, 150.

However, we provide both wired metering bars and the plain smoothing bars to match the requirements of all widths for adhesive and production coaters.

Mayer wire applications:

• ✓ Adhesive
• ✓ Boards
• ✓ Cellulose
• ✓ Ceramic Colors
• ✓ Driers
• ✓ Duplicating Inks
• ✓ Emulsions
• ✓ Fillers
• ✓ Floor Polishers
• ✓ Lacquers
• ✓ Metallic powders
• ✓ Oils
• ✓ Papers
• ✓ Photographic papers
• ✓ Pigments
• ✓ Plastics
• ✓ Printing inks
• ✓ Resins
• ✓ Varnishes
• ✓ Waxes and Hot Melts

Available sets for Ordering:

Small Starter Set:

1 small impression bed (coating area 11 x 18cm)

8 short Bars 1-8 (specify bar nos if needed)

Large Starter Set:

1 large impression bed (coating area 22 x 34cm)

9 long Bars 0-9 (specify bar nos if needed)

Every item can be ordered individually.

Bottom line:

The Mayer Bar technology was first introduced for coating the carbon and waxed paper, and since then it has never gone out of fashion. The technology has faced several advancements over time and is thus popular among generations. But finding the right Mayer bar or bar coaters can be an uphill struggle, so it is always advisable to rely upon the experienced Mayer Bar Manufacturers, Mayer Bar Suppliers, Mayer Bar Distributors like TFT industries. With us, you get the prime quality, maximum selection, and the best value for your money. Just give us a call and get your best quote now.