Turn-key solutions for industrial thin film deposition
Our K300 and K600 systems take spatial ALD technology from the lab to your production floor, offering atomic-level precision at manufacturing scale. Built for industrial settings such as packaging, batteries, and photovoltaics, our roll-to-roll equipment combines performance with the reliability, easy maintenance, and efficiency that modern manufacturing requires.
Our spatial ALD thin film machines operates continuously at atmospheric pressure. This fundamental difference translates into faster throughput, lower operating costs, and simpler integration into existing production environments.
We offer two models to match different production needs, from pilot lines and specialised manufacturing to high-volume production.
For more details, download our product sheet.
Key features of our spatial ALD thin film machines
Low cost operation
Operating at atmospheric pressure means no expensive vacuum systems are needed. This reduces capital costs, energy use, and maintenance requirements. Atmospheric operation also enables inline integration with other processes.
Multiple materials, one process
The machines can deposit multiple layers of different materials in a single continuous process, creating complex layer structures whilst maximising throughput and reducing substrate handling.
Built for manufacturing
The systems are designed for high uptime with straightforward maintenance and consistent performance in volume production environments.
Total cost of ownership
The real measure of value is the total cost over the equipment’s lifetime, and this is where our super spatial ALD thin film machines shows its worth. The total cost of ownership per square metre produced is substantially lower than conventional technologies.
High quality and density of the super spatial ALD layers make that you need thinner layers to achieve better result, reducing material cost. High precursor utilisation reduces material waste and consumable costs even further. With the absence of energy-intensive vacuum pumps, our equipment significantly cuts operating costs compared to conventional ALD or CVD systems. High throughput combined with high uptime means more coated area per day, spreading capital costs across greater output.
Low-temperature processing cuts energy consumption whilst enabling work with temperature-sensitive substrates. Straightforward maintenance means smaller service teams and lower ongoing costs. When calculated per square metre of coated material, the economics are competitive for industrial-scale thin film deposition.
K300 and K600: Two systems for different scales
We offer two models to match different production needs, from pilot lines and specialised manufacturing to high-volume production. Both systems handle a broad range of flexible substrate materials and can be customised for specific applications. Whether you’re coating temperature-sensitive polymers or robust metal foils, the equipment delivers consistent results across various materials.
K300: For pilot and specialised production
The K300 works well for R&D transitioning to pilot production, and for specialised manufacturing where precision is priority.
K600: For larger production volumes
The K600 offers higher throughput for industrial-scale manufacturing whilst maintaining the same coating quality.
From sample to production
Adopting new technology requires careful evaluation, so we offer several ways to assess whether our machines fits your needs. You can request a sample coating on your substrate or visit our facility for a live demonstration and a conversation with our technical team.
To support a smooth transition into production, we provide consulting and integration assistance. Our product specialists help define your requirements, recommend suitable configurations, and guide you from site planning to start-up.
Contact us to discuss your application, request sample testing, or schedule a demonstration.
FAQs Scaling and Production
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Super spatial ALD increases deposition speed by a factor of 1000 compared to traditional temporal ALD processes. The system achieves ALD process speeds of 10-800 cycles/m²/min with web speeds up to 30 m/min, enabling true industrial-scale throughput for roll-to-roll manufacturing.
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Kalpana Systems offers two models:
K300: Designed for flexible electronics and solar cell applications. Supporting web widths from 300-600 mm and up to 4 different precursors.
K600: Optimized for high-speed applications like batteries and packaging Supporting web widths up to 1500 mm.
These roll-to-roll systems are compatible with integration into existing production lines.
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One of the key advantages of the helical design is its compact footprint compared to conventional spatial ALD systems, which often require large floor space that isn't available in existing facilities. The orientation and roll-to-roll configuration make the system suitable for integration into standard manufacturing environments.
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No, super spatial ALD operates at atmospheric pressure, eliminating the costs and complexity associated with vacuum systems. This significantly reduces capital expenditure, operating costs, and maintenance requirements compared to vacuum-based thin film deposition technologies like PVD or PECVD.
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Installation and site acceptance testing typically take 6-9 months from order to operational deployment.
FAQs Economics
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Super spatial ALD offers a compelling business case through the combination of high throughput and continuous processing, which significantly lowers the cost per square meter of applied thin film. Valuable raw materials are used efficiently, reducing precursor costs, while the absence of vacuum requirements keeps both capital and operating expenses low.
Excellent gas separation ensures stable, consistent processing with minimal downtime.The technology is also significantly more energy-efficient than current coating methods, and its compact footprint means it can be integrated into existing facilities without major infrastructure changes or conversion costs.
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Production processes using super spatial ALD are significantly more efficient, supporting a sustainable production. Using resource materials with atomic level precision reduces material waste and enables efficient use of scarce and precious materials. The technology uses significantly less energy than alternative deposition methods. Super spatial ALD extends product lifetimes in batteries, solar PV and OLED. In packaging, it enables full recyclability.
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Super spatial ALD delivers a strong return on investment from multiple perspectives. In the production process, it cuts production costs through reduced material usage and lower energy costs, while delivering industry standard throughputs. Super spatial ALD also contributes to improved product quality and lifetime. Additionally, advanced coatings offer access to premium market segments that enable higher margins. Finally, it makes it easier to meet sustainable regulations and avoid compliance costs.
Take the lead in your industry
Whether you’re developing batteries, flexible solar cells, OLED displays, or high-barrier packaging, our thin film machines can help take your innovations from lab to production.