New Capability · Development & Pilot Projects
Microencapsulation & Precision Coating
Microencapsulation, precision coating, converting and single-dose packaging under one roof in New York. Our new coating line applies functional ingredients directly to nonwoven substrates, so a dry sheet can carry a cleanser, a fragrance or a skincare system and release it when it is used.
DEVELOPMENT & PILOT PROJECTS ACCEPTED NOW · HOLBROOK, NEW YORK
Where the line stands
✓Faustel LabMaster pilot coater/laminator installed in Holbrook, New York
✓Commissioning and application trials under way
✓Development and pilot projects quoted today
✓Commercial production follows successful qualification trials
We would rather tell you this up front than discover it on your timeline. Every project starts as a feasibility trial on your formula, your substrate and your finished format.
Platform
Faustel LabMaster
Web width
Up to 14 in (356 mm)
Line speed
10–100 ft/min
Coating systems
Water, solvent, hot-melt
The Technology
What microencapsulation does on a nonwoven sheet
Microencapsulation holds an ingredient inside microscopic shells or a protective matrix, so it stays put until something releases it. On a wipe or sheet, that means an active can sit dry on the fibres through storage and shipping, then come out at the moment of use instead of evaporating, migrating or reacting in the pack.
What triggers the release is decided by the capsule chemistry, not by the machine. Depending on the system chosen, a product can be designed to release with friction, water, pressure or heat. A rub-to-release fragrance sheet and a just-add-water body wash sheet use different chemistries, and each one is validated on its own.
How our process differs
We do not buy finished microcapsules and stick them to a sheet. We prepare the microencapsulation solution and apply it through the precision-coating process, and the capsules form directly on the selected substrate as it is coated and dried. The coated web can then be laminated, converted into sheets and individually packed on the lines we already run for private label wet wipes.
That last part is the practical difference for a brand. Instead of buying coated rolls from one supplier and having them converted and packed somewhere else, the solution, the coating, the converting and the single-dose packaging happen in one building, with one team responsible for whether the finished sheet works.
One roof, start to finish
✓Microencapsulation solution prepared in-house or from your formula
✓Capsules formed on the substrate during coating and drying
✓Dry-bond and wet-bond laminating
✓Converting to finished sheet sizes
✓Individually wrapped sachets, pouches, cartons or coated rolls
Whether a given coated web can run straight onto our sachet line is confirmed in the pilot, because sheet size, folding, thickness and loading all have to be compatible.
Applications
What the coating line is built for
These are the applications we are quoting as development and pilot programs today. Each one still has to pass formulation, coating, activation, drying, stability and packaging trials before it becomes a commercial product.
01
Fragrance-infused sheets
Rub-to-release scent on personal-use sheets, linen and laundry sheets, in-pack scent inserts and retail samplers. One of the strongest first applications for the line.
02
Water-activated cleansing sheets
Dry body wash and cleansing sheets and towels that lather when the user adds water. See the product range.
03
Micellar & skincare sheets
A dry facial sheet that rehydrates with a little water. A dry counterpart to our facial wipes for brands that want to drop the liquid.
04
Cooling sheets & towels
Encapsulated cooling agents or menthol-free evaporative constructions, a dry variant of our cooling wipes.
05
Activated dry cleansing cloths
A coated upgrade of the plain dry cleansing cloth, with the cleanser loaded on the cloth instead of added by the user.
06
Specialty coated rolls & toll coating
Semi-finished coated nonwoven rolls for converters, or coating applied to a substrate you send us, specified per project.
Shampoo and dry shampoo sheets, deodorant sheets and temporary hair color root touch-up sheets can also be reviewed as custom development projects. We present them as development work, not as finished products, until product-specific prototypes have been validated.
Specifications
Coating line specifications
The figures below are the published platform values. The ones not listed, such as minimum web width, substrate weight range and coat weight, depend on the installed configuration and your formula, so we establish them in the trial rather than quote them in advance.
| Equipment | Faustel LabMaster pilot coater/laminator, a modular pilot and narrow-web coating and laminating line |
|---|---|
| Web width | Standard platform 12 in (300 mm), up to 14 in (356 mm) |
| Line speed | Roughly 10–100 ft/min (3–30 m/min), set by substrate, coat weight and drying |
| Coating chemistry | Water-based, solvent-based and hot-melt systems |
| Coating methods | Roll coating, with interchangeable heads on the platform including slot-die, comma-roll, knife-over-roll, reverse-roll, flexographic and rotary-screen. The method for your project is confirmed in the trial. |
| Coating sides | One-side coating, plus dry- and wet-bond laminating |
| Coverage | Full-width coating; patterned application evaluated per project |
| Substrates | Nonwovens, paper, film and foil. Spunlace, airlaid and other nonwovens are qualified by trial on roll quality, strength and porosity. |
| Formulation | Your formula, or development coordinated by us |
What we can deliver
- Individually wrapped sheetssingle-dose sachets, our core format
- Multi-count pouchesdry sheets in resealable packs
- Folding cartonsindividually wrapped sheets, boxed
- Canistersfor dry sheet counts
- Coated rollssemi-finished, for converters
Heat-sensitive actives are assessed formula by formula, because every coated product passes through a drying stage.
How It Works
How a development project runs
A new coated product is engineered, not picked from a catalogue. This is the sequence every project follows.
01
Brief
Tell us the active or formula, how it should release (water, friction, pressure or heat), the substrate you have in mind, the finished format and the target quantity.
02
Feasibility review
We check the formula against the coating and drying process, the substrate and the packaging, and flag anything that needs reformulation or a separate regulatory review.
03
Pilot coating trials
The solution is coated and microencapsulated on candidate substrates, and coat weight, drying and activation are tuned on the line.
04
Development samples
First feasibility samples typically take 4–8 weeks once the formula brief and materials are in hand. New formulas or specialised active systems can take longer.
05
Validation
Stability, packaging compatibility and performance testing for the specific formula, substrate and pack. Shelf life and claims come from this data, never before it.
06
Production
Commercial MOQ, pricing and lead time are quoted once the trials show what the product needs to run.
Scope
Which products we take on first
The coating machine does not decide how a product is regulated. Its intended use and its claims do. So we start with cosmetic and general consumer products: cleansing sheets, fragrance sheets, skincare sheets that cleanse or moisturise, cooling and refreshing sheets, and coated nonwovens for other converters.
Products that would be regulated as OTC drugs, EPA-registered pesticides or medical devices need their own review of formula, claims, facility and registration before we accept them. That covers antiperspirant, SPF, acne-treatment, antiseptic and insect-repellent sheets, among others. If your concept is in that group, tell us in the brief and we will say plainly whether and how it can proceed. Our guide to wet wipes regulations explains how FDA, EPA and FTC rules split by product type.
The same discipline applies to claims. Shelf life, scent duration, cooling time, “preservative-free” and similar statements depend on the final formula and its test results, so they are set at the end of development rather than promised at the start.
A good brief includes
✓The active, fragrance or formula, and who supplies it
✓How the product should activate
✓Substrate preference and sheet size
✓Finished format: sachet, pouch, carton, canister or roll
✓Target quantity and launch window
Development work is quoted per project once we have reviewed the brief. Commercial MOQ follows the trials, when the coating and packaging requirements are known.
FAQ
Microencapsulation & coating FAQ
What is microencapsulation?
Microencapsulation surrounds tiny amounts of an ingredient with a shell or protective matrix, so the ingredient is held in place and released later by a trigger such as friction, water, pressure or heat. On a nonwoven sheet it lets a dry product carry a fragrance, cleanser or skincare system until the moment it is used.
Is the coating line in commercial production?
Not yet. The Faustel LabMaster line is installed and being commissioned, with setup and application trials under way. We are accepting development and pilot projects now, and commercial production for each product follows successful qualification trials.
Do you make the microcapsules or buy them?
We prepare the microencapsulation solution ourselves and apply it through precision coating. The capsules form directly on the chosen substrate during coating and drying, rather than being bought in as finished capsules and attached afterwards.
Can I use my own formula or fragrance?
Yes. We can work from a customer-supplied formula, or a fragrance from your own fragrance house, or coordinate development for you. Every formula is reviewed for compatibility with coating, drying, stability and packaging, and supplied fragrances need their technical and safety documentation.
How long do development samples take?
First feasibility samples typically take 4–8 weeks once the formula brief, substrate and raw materials are available. Custom formulas, custom fragrance work or specialised active systems can extend that.
What does a development project cost?
It depends on the formula, the substrate, the coating method and the finished format, so development and pilot work is quoted per project after we review your brief. Project-specific setup, tooling or cleaning charges may apply, and commercial MOQ is quoted once the trials are complete.
Can you coat a substrate we supply?
Yes, as toll coating. We confirm roll width, diameter, core, web strength, cleanliness and coating receptivity first, then check compatibility with the chosen solution and drying conditions.
How long will the scent or active last?
That is established by testing, not promised in advance. Shelf retention and in-use duration depend on the ingredient, the encapsulation system, coat loading, substrate and packaging, so they are set from stability and performance data on the final product.
Related products and services
The coating line adds to the manufacturing we already do; it does not replace it.
New category
Activated Dry Sheets & Towels
Dry sheets and towels that activate with water or friction, made on this line.
View details →
Product
Dry Wipes
Plain, unsaturated nonwoven cloths for patient care, optics and industrial use.
View details →
Services
Private label, contract manufacturing & sachet filling
The converting and packaging the coated product flows into.
View details →
Have a coated sheet in mind?
Send the active, how it should release, the substrate and the format. We will tell you what the trial needs to prove.