Custom Manufacturing Process


Material Expertise

raw_materials_narrowBased on decades of experience, our scientists and product engineers are experts in the selection and application of related raw materials and components.  We work closely with our customers during a project’s discovery phase to identify and qualify the ideal component materials.

Adhesives Research also develops custom release liners to meet specific adhesive and processing requirements. Our high-quality release liners are FDA compliant, and are available in a variety of substrates with tailored release levels. AR’s release liner capabilities include:

  • Single- or double-coated liner systems
  • Polyester films
  • Polyethylene films
  • Papers
  • Poly-coated papers
  • Clean room processing

Polymer Synthesis

polymer_synthesis_narrowPolymer formulation and synthesis is a core capability at Adhesives Research. This capability provides us the flexibility to create new adhesives as performance needs evolve or more specific functional properties are needed. When an existing adhesive can’t quite meet the need of an application, our synthesis team will create one that hits the mark.



Mixing & Compounding

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Adhesives Research compounds adhesives and polymers in segregated facilities. We produce batches sizes ranging from 5 to 600 gallons, comprised of a wide variety of potential materials, including:

  • PIBs
  • Acrylic copolymers
  • Excipients
  • Conductive dispersions
  • GRAS & compendial monograph components
  • Silicone resins
  • Block copolymers
  • Rubber/resin blends
  • Polymers for dissolvable films

Casting & Drying

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Our state-of-the-art U.S. and European manufacturing facilities feature 21 coating lines, including five isolated line and two cGMP processing lines for our ARx division.  The depth of our coating technology provides a variety of roll and die coating techniques for casting and curing aqueous, solvent and 100% solids coatings in widths up to 56”.



Types of Coatings

  • Solvent-based systems
  • Water-based systems
  • 100% solids
  • Dissolvable films

Coating Techniques

  • Reverse roll
  • Knife-over-roll
  • Slot die technology
  • Gravure

Drying/Curing Techniques

  • Convective heat (impinged air)
  • Infrared with applications
  • Ultra-violet

Slitting & Packaging

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Multiple slitting techniques are utilized to finish master rolls to each customer’s product specification.  An isolated environment is utilized for slitting, labeling and packaging finished rolls ranging in widths from 54” to less than 1”. 

 



Testing of Raw Materials, Work-in-Progress and Finished Roll Goods

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Our on-site quality assurance, quality control and analytical laboratories ensure product quality at multiple stages during the manufacturing process.  Incoming raw materials and components are evaluated when received and are completely traceable at each stage.

Work-in-progress is evaluated, tested and released after every step of our manufacturing process. Finished roll goods are tested prior to release to assure that all products meet or exceed our customers’ expectations and specifications.  Certified test reports (CTRs) or certificates of analysis (CoAs) may be provided upon request.