Finite coating thickness of Prandtl fluid in non-isothermal reverse roll coating process

Purpose The coating process is broadly employed in the manufacturing of wallpapers, adhesive tapes, wrapping, protection of fabrics and metals, X-ray and photographic films, beautification, books and magazines, film foils, magnetic records, coated paper, etc. Design/methodology/approach In this study, an incompressible flow of non-Newtonian fluid is modeled to inspect the rheological behavior of finite coating thickness in the reverse roll coating process. With the assistance of lubrication approximation theory (LAT), the dimensionless form of governing expressions is simplified. Exact solutions for distributions for velocity, flow rate, temperature and pressure gradient attained utilizing perturbation technique and their variation is presented as well as discussed in graphs. Meanwhile, some important factors from an engineering perspective including coating thickness and transition point were calculated mathematically and are displayed in a tabular manner. Also, streamlines are drawn to observe the flow pattern. Findings Prandtl fluid parameters provide a controlling factor to regulate the flow rate, velocity, coating thickness, and pressure gradient leading to an efficient coating process. Moreover, the Brinkman number and Prandtl fluid parameters significantly improve the temperature distribution. Originality/value In the literature, this study fills a gap in the theoretical prediction of coating thickness rheologically influenced by Prandtl fluid in reverse roll coating process.