Coating, lamination, calendaring and embossing lines

Premium coating, lacquering and embossing solutions

With decades of experience, Matthews Engineering offers precision-engineered converting lines tailored for artificial leather production – from coating to finishing. From top coat to adhesive application, our reverse coating process ensures flawless results on PVC/PU substrates up to 2,400 mm wide.

Whether for luxury bags, furniture, footwear, or automotive interiors, our systems guarantee high reproducibility and superior product quality. Versatile lines allow embossing, laminating, and multilayer combinations—ideal for diverse applications and materials. High-speed production up to 50 m/min boosts your efficiency and competitiveness.

Anode & Cathode Expertise

We understand that high-performance batteries demand precision at every layer – starting at the electrode level. Our engineering solutions address the unique challenges of each electrode, enabling manufacturers to achieve superior conductivity, uniformity, and mechanical integrity in dry electrode manufacturing.

Anode

Graphite, silicon-graphite blends, and hybrid powders – each tailored for optimal dry electrode integration, supporting higher energy density and cycle life. We help you balance conductivity with mechanical stability for robust anode layers.

Cathode

LFP (lithium iron phosphate), NMC (lithium nickel manganese cobalt oxide), and high-nickel cathode materials – our solutions promote uniformity and high conductivity even in thick, high-loading electrodes, driving improved power output and manufacturing efficiency.

Conductive Powders Expertise

At our facility, we offer hands-on conductive powder testing tailored for dry electrode development.

The process begins with powder samples provided by the customer. These powders are processed on-site through calendering to form a self-supporting film. From this film, we punch out samples for in-house analysis. All measurements are conducted using state-of-the-art instruments directly on-site, allowing for fast turnaround.

In close collaboration with the customer, we evaluate and optimize these results to support improved dry coating performance and material efficiency. This enables informed decisions early in the development process – helping to reduce scaling risks and increase consistency in downstream manufacturing.

Scalable Production Lines for High-Performance Metal Manufacturing

Embossing calenders

superior surface finishes on metal sheets, strips, and plates — achieving consistent textures and patterns essential for applications in automotive, appliances, and architecture.

Lamination lines

purpose-built for producing high-quality composite and sandwich materials, enabling the precise bonding of metals with other substrates for lightweight, durable, and functional components.

tailored technologies across every segment of the nonwoven industry – from hygiene and femcare to medical, wipes, and agricultural textiles.

Web Handling

Consistent product quality begins with controlled web dynamics. Our web handling systems for guiding, tension control, and precision cutting are tailored to the diverse characteristics of nonwoven substrates – from lightweight spunbond to multi-layer composites. With advanced sensors, adaptive controls, and rugged mechanics, we ensure smooth processing, high uptime, and reduced waste.

Integrated into new or existing lines

designs and delivers advanced production lines that help paper and board manufacturers achieve consistent quality, high throughput, and functional excellence.

• Writing, printing, and copier papers
• Packaging board and corrugated base paper
• Specialty and technical papers
• Tissue and hygiene papers
• Graphic fine papers and decor papers

Coating lines

apply functional and barrier layers that enhance paper performance, while our embossing lines create decorative and functional patterns with precision textures.

Lamination lines

enable the production of multi-layer paper products with superior bonding, and our printing and lacquering lines provide premium surface finishes and protective layers.

Laboratory calenders

For R&D, prototyping, and pilot-scale production, thus flexibility and precision manufacturers need to innovate with confidence. Each system is engineered for seamless integration, energy efficiency, and reliable performance to support future-ready paper and board manufacturing.

for industries ranging from packaging to construction

• Flexible packaging films
• Technical films
• Rigid films and sheet materials
• Shrink films and stretch films
• Decorative and furniture films
• Agricultural and construction films
• Coating self-adhesive films and papers

Coating Solutions for Self-Adhesive Films and Papers

When it comes to coating self-adhesive films and papers. design and delivery of custom coating systems for virtually every coating variant, tailored to specific products and production processes.

Whether producing conventional or technical adhesive tapes, graphic and decorative products, or protective films, our coating technologies provide safe, consistent, and efficient processes. With working widths from 300 to 3,500 millimeters, we support all industrial production speeds and requirements.

Laminating Technologies for multi-layer films and functional coatings

Our systems enable the application of functional layers, adhesives, and protective finishes with uniform thickness and superior bonding strength.

We provide laminating solutions for multi-layer film structures — from standard composites to complex specialty films — supporting applications in packaging, technical films, and decorative surfaces.

Designed for compatibility with a wide range of substrates, including PE, PET, PP, and PVC, our solutions help manufacturers meet the highest standards of product quality, efficiency, and performance.

fully integrated solutions that combine coating, laminating, embossing, and calendering processes to create high-performance materials

Versatile Coating Lines for Superior Performance

precision coating systems designed to produce high-quality finishes across a wide variety of technical textile substrates.

Our solutions enable reliable coating on banner fabrics, membranes, tarpaulins, artificial leather, conveyor belts, and more. With flexible working widths ranging from 1,400 mm to 5,400 mm

Laminating Lines for Multi-Layer Solutions

Our advanced laminating lines empower you to create robust multi-layer technical textiles with ease. Whether combining PVC or PU films with textile webs or constructing heavy-duty laminates for conveyor belt applications

 Our machinery accommodates working widths from 1,400 mm to 5,400 mm and is engineered for strength, high line forces, and durability

Embossing and Smoothing Technologies

creates precise three-dimensional textures and refined finishes that enhance both the functional and visual qualities of materials.

Ideal for artificial leather, industrial and conveyor belts, membranes, and protective fabrics, our technologies help you achieve superior product differentiation through custom textures, matting, or smoothing.

Calender Coating and Specialized Lines

Our calender coating lines set the standard for high-precision technical textile production. Matthews Engineering melt-roll calender systems and specialized combined lines deliver exceptional coating performance for open and closed woven or knitted fabrics.

 These solutions are ideal for industrial, architectural, and specialty applications where technical and aesthetic specifications are critical. We integrate embossing, lacquering, and pre-coating stages as needed, enabling seamless production workflows that meet even the most complex requirements.

Tissue production and converting machines

Toilet paper: For consistent ply bonding, roll softness, and speed – and deliver systems that optimize both quality and efficiency.

Kitchen roll: For high-absorbency products with strong structural integrity, our machines ensure reliable performance across embossing, calendering, and web handling.

Handkerchiefs: High-speed converting, gentle embossing, and quick changeovers are key

Napkins:Tailored solutions that meet the design and durability demands of napkin production.

 Softness Meets Strength

Our Tissue Embossing Calender systems combine precision embossing with modular flexibility to meet the demanding needs of tissue, towel, and hygiene producers. Whether you’re focused on ply-bonding strength, tactile softness, or intricate design detail, Matthews Engineering empowers your process with intelligent, high-performance embossing.

From twin embossing to point-flat, point-point, and matched steel options, each calender is engineered to deliver consistent, repeatable results—seamlessly integrated into your line or built to scale with you.

Thanks to decades of experience in web-based processing and high-precision roller systems, we develop customized calendering solutions that meet the evolving requirements of the converting and energy industries.

advanced calendering systems that enable precise control over thickness, density, and surface finish. Whether you’re processing plastic films, nonwovens, paper, or electrode materials, our calendering technology ensures maximum uniformity, stability, and performance – even under high speed and thermal load.

Energy Applications

Multi-Roll Calender 

Designed for dry electrode processing in low-volume production lines, this multi-roll calender ensures uniform densification without solvents. Its compact, modular layout is ideal for pilot-scale runs or early-phase commercialization.

Calender for continuous coated battery electrodes 

High-speed, precision calendering for roll-to-roll coated electrodes – ensuring uniform thickness, density, and mechanical integrity in large-scale lithium-ion production.

Calender for intermittent coated battery electrodes 

Designed for intermittent patterns and pulse-coating lines, this calender ensures stable compaction and smooth transitions between coated and uncoated web sections.

Laboratory Calender GK 300L 

With a configurable setup, vertical or horizontal positioning, and a wide range of optional components, the GK 300 L adapts to your testing environment and application needs.

pre-metered self-metered or post-metered coating systems, gravure or smooth roll, slot-die or curtain coating, knife coating or mayer bar coating technologies, our modular systems deliver exact material deposition – micrometer by micrometer – with absolute consistency across the full web width.

From battery separator films to decorative surfaces and technical films, our custom-engineered coating equipment integrates automation, advanced drying technologies, and real-time process monitoring

In-house Development Centers demonstrate over 70 coating methods, resulting in ultra-precise, durable systems with micron-level accuracy – built for 24/7 industrial operation. Solutions cover all coating types, including adhesive, hotmelt, silicone, lacquers and more, with rollers that can be heated, cooled, smooth or engraved.

Coating widths range from 125 mm to 5,400 mm, with speeds exceeding 1,000 m/min and application weights from less than 1 g/sqm to  more than 1,000 g/sqm. Modular line concepts (1–4 stages) enable flexible inline/offline configurations and rapid changeovers via cassette technology.

Key innovations include PGS® pressure chamber systems for uniform TopCoats and air-free application, as well as vertical semi-flexo coating for a wide viscosity range without roll changes. The multilayer curtain coater applies multiple layers simultaneously with minimal tolerances, reducing material use and waste.

Key Features 

Coating Lines for Battery Separator Film 

Our coating systems enable ultra-thin, uniform coatings on separator films used in lithium-ion batteries – with integrated tension control, low-solvent operation, and inline inspection capabilities.

Battery Separator Film Excellence

From high performance pressure-chamber micro-gravure ceramic coating systems to fully integrated drying and web handling, every module is built to ensure non-contact processing on the coated side and low-tension threading, as well as wrinkle-free and defect-free output, maintaining the precision and repeatability that modern gigafactory environments demand.

Technical Specifications

For a broad range of substrates, even under high-temperature and high-pressure conditions, our systems deliver consistent surface quality for both optical and haptic effects. With flexible heating/cooling systems, advanced roller geometry, and custom drive technology, our machines are ideal for decorative films, hygiene products, automotive interiors, and more.

Hot Embossing Calender 

Achieve high-speed, precision embossing on plastic films with intelligent thermal control, rapid roll changeovers, and customizable surface textures—perfect for packaging, hygiene, décor, and more.

Tissue Embossing Calender 

Engineered for high-speed, high-fidelity embossing on delicate tissue and hygiene substrates. Designed for soft-touch effects and consistent roll-to-roll performance.

Metal Embossing Calender

Robust calender system designed for precision embossing on metal foils and metal sheets. Ideal for automotive, decorative, and industrial applications requiring durable textures.

Embossing Calender for Bipolar Plates

Designed specifically for metal and graphite bipolar plates, our embossing systems reduce complexity, enhance quality, and scale with you from pilot lines to full production.

Sleeve Change Calender

Designed for agility, this system enables rapid sleeve changeovers without compromising embossing accuracy—built for dynamic design cycles.

Features 

Custom Temperature Control: Our systems offer independently controlled heating zones, oil or electric thermal systems, and integrated cooling for precise temperature profiles — critical for consistent embossing across variable substrates and multi-layer materials.

Modular Construction: Flexible, future-proof design with modular machine architecture allows for easy expansion, retrofitting, or integration into existing production lines. Tailor your setup with unwinders, web aligners, pre-heating, embossing stations, and post-treatment modules.

High-Precision Roller Systems: Our embossing rollers are engineered to sub-micron tolerances with customized surface engravings — from fine textures to deep 3D reliefs — enabling crisp detail and perfect registration even at high line speeds.

Efficient Changeovers: Quick-change roller systems, recipe memory, and automated nip and gap adjustments reduce downtime and enable fast job transitions. Ideal for short-run flexibility and multi-design workflows.

Validate materials, processes & embossing performance 

Our Development Center is where innovation meets application. From pilot-scale trials to material behavior analysis and prototype optimization, we offer a collaborative environment to engineer, test, and fine-tune your coating solutions — all before they hit full-scale production. It’s where future-ready ideas become proven, precision-engineered realities.

Designed for compressing, embossing, laminating, or powder processing, our systems give researchers the flexibility to run repeatable experiments and simulate industrial conditions – all within a small lab footprint.

versatile and scalable range of laboratory equipment tailored for R&D, pilot-scale testing, and process validation. Whether you’re developing advanced battery materials, optimizing converting parameters, or running high-fidelity print simulations – our modular systems deliver precision, flexibility, and industrial relevance at lab scale

Laboratory Calender GK 300 L

With a configurable setup, vertical or horizontal positioning, and a wide range of optional components, the GK 300 L adapts to your testing environment and application needs.

Laboratory Calender GK 300 L for battery electrodes

Compact, configurable calendering unit for R&D and pilot-scale applications – perfect for material testing, parameter optimization, and pre-production validation.

Laboratory Calender GK 300 L 6R for battery electrodes

A high-precision, six-roller calender system designed for R&D and small-batch production. Ideal for material validation, parameter optimization, and pilot-scale trials – offering full control over compaction, temperature, and web handling in a compact footprint.

Ingenio laboratory printing machines

The ingenio laboratory printing machines are compact proofing devices for realistic printing simulations and efficient color testing in packaging development.

advanced laminating lines designed to deliver clean, consistent layer bonding across a wide range of materials and applications — from flexible packaging and technical textiles to automotive interiors and decorative applications. Whether your process involves thermal, pressure-sensitive, or multi-layer lamination, our lines are built for flexibility, durability, and repeatability, with the ability to run in open mode when lamination isn’t required

designed for low-elongation, wrinkle-free processing with precise web tension and temperature control – ideal for sensitive materials. Known for decades for multilayer lamination expertise, the company develops custom solutions with working widths from 125 mm to 5,400 mm and temperatures up to 200 °C. Systems support high line forces, adjustable nip pressure and optional open operation

Features

Laminating Calender for Catalyst Coated Membranes

Our laminator ensures defect-free bonding of membranes and layers – supporting efficient, scalable hydrogen fuel cell manufacturing.

advanced printing and lacquering lines that combine performance, design flexibility, and precise control. Whether you’re applying lacquer or ink to floor coverings, wallcoverings, or high-performance films — our machines deliver superior quality at industrial speed.

With modular design, intuitive operation, and smart automation, our systems adapt to your materials and production needs

With production speeds of up to 100 m/min and working widths up to 5,400 mm, our systems are ideal for small decorative film runs and large-scale manufacturing. Inline and offline systems with up to twelve printing units allow for non-stop design changes — even during live production.

Designed for water- or solvent-based inks and lacquers, these machines offer coating weights from 0.5 to 60 g/m² with maximum register accuracy, fast setup, and low scrap rates. Fully automatic gap and pressure controls, recipe management and register systems (even without marks) ensure defect-free, repeatable surface finishes. Flexible applicators allow forward/reverse lacquering, direct/indirect coating and fast changeovers via trolley systems.

With working widths up to 5,400 mm and compatibility with all industrial speeds, the systems are suitable for both small and large formats. Inline concepts with up to 12 printing units support continuous design changes, while offline systems target high-speed printing. Advanced visualization keeps web tension monitored at all times. Expertise in ATEX, explosion protection and exhaust treatment complements tailor-made solutions—including modules for smoothing or embossing.

Features

Industrial Inkjet Printing for Decorative Surfaces 

The unique industrial inkjet printing technology is most suitable for decorative products such as wallcoverings, decorative films, floor coverings and similar PVC-based products. There is no need for specific ink reception layers, primer coatings or any pre-treatment of the printing substrate. The special ink is absorbed by and embedded in the wet plastisol. The single-pass technology is perfectly suitable for integration into existing industrial printing lines. It is furthermore available as a dedicated stand-alone printing line, off-line or near-line

We design and build precision-engineered equipment solutions that align with your specific production requirements. Our Purpose Built Equipment is developed to integrate seamlessly into your overall workflow, support a wide range of materials and performance parameters, and adapt as your needs evolve. From material handling to web control, thermal processing to system automation—each component is engineered to deliver consistent, reliable performance.

Our core areas of expertise:

Drying Systems 

High-precision drying for demanding applications

From banner fabrics to decorative films, our energy-efficient dryers deliver pinpoint accuracy and consistent performance across every inch of your web. We offer a comprehensive range of custom-designed dryers, precisely built to match your material characteristics, drying profiles, and performance expectations.

Whether you’re drying heavy coatings, solvent-based products, or self-adhesive films, we deliver thermal solutions that ensure perfect quality and sustainability.

• Top/Bottom Air Dryers with CTS-TP Nozzles:
• Infrared (IR) Field Dryers and Foaming Ovens:
• Nozzle Circulating Air Systems (Internal/External):
• UV Dryers and Cleanroom/GMP-Compliant Dryers:
• Floatating Dryers with OLBRICH Float Nozzle Technology:

Technical Specifications

Winding Solutions 

Maximum flexibility, minimal tension, and roll perfection — our winding systems support speed, precision, and sensitive substrates. Designed to integrate seamlessly into your line, each system delivers crease-free, tension-optimized winding across diverse materials including films, textiles, papers, and self-adhesive products.

From manual setups to fully automated turret solutions, we engineer winding performance around your unique process.

• Turret Winders (Manual to Automated)
• Flying Splice & Residual Length Optimization
• Shaftless and Mandrel-Driven Winding
• Contact & Circumferential Rewinders
• Web Accumulators & Coreless Winding Options

Technical Specifications

Web Handling 

Smart web handling ensures precision movement, tension control, and flawless substrate delivery through every process stage. Our systems are engineered to handle even the most sensitive materials—thin films, stretchable substrates, or multi-layered webs—while maintaining consistency, minimizing waste, and reducing downtime.

• Precision Tensioning Systems for Delicate Webs
• Web Guiding Sensors with Lateral Correction
• Anti-Wrinkle and Air Bar Spreading Systems
• Dancer and Looping Systems
• Static Discharge Control (Ionizers)

Drive & Control Technology

Fully integrated drive and control systems, tailored for safety, uptime, and performance—built on decades of precision automation expertise. From intelligent drives to intuitive visualization, our electrical and software engineers develop full-stack architectures that ensure smooth, synchronized operations.

Whether you’re building a new line or upgrading an existing one, we provide the tools and support to optimize your process and extend equipment life.

• Drive System Conception & Switchgear Design
• CPU and PLC Software Engineering
• SCADA/Visualization Systems
• Remote Diagnostics & Lifecycle Service
• IQ/OQ Support for Regulated Industries