Method of flexographically producing a faux galvanized metal finish on a substrate

A method of flexographically applying a faux galvanization coating to the surface of a coiled steel sheet, the method comprising:

• advancing a leading edge of a coiled metal substrate into the feed end of a flexographic coil coating line;
• advancing the metal substrate through at least one cleaning section within the coating line;
• advancing the metal substrate through a pretreatment station;
• advancing the metal substrate through a pretreatment oven within the coating line which raises the temperature of the substrate to approximately 300° F.;
• advancing the metal substrate into a flexographic roller with a flexographic roll pattern;
• applying with the flexographic roller a spangle pattern of polyvinylidene fluoride (PVDF) atop the metal substrate with the flexographic roller;
• advancing the metal coil substrate with the spangle pattern into an oven;
• heating the metal coil substrate and applied PVDF pattern to a peak metal temperature in the range of about 455° F. to 475° F. and maintaining a residence time in the range of about 40 to 60 seconds;
• advancing the metal coil substrate with the applied PVDF pattern to a quench station to cool the metal coil substrate;
• advancing the quenched metal coil substrate with the applied PVDF pattern to a flexographic roller for application of a fluoroethylene vinyl ether (FEVE) semi-transparent coating;
• flexographically applying the FEVE semi-transparent coating to the substrate over the PVDF pattern;
• advancing the metal coil substrate with the PVDF pattern and FEVE coating into an oven to achieve a substrate peak metal temperature in the range of about 470° F. to 490° F. to volatilize solvents from the applied FEVE coating;
• advancing the heated metal substrate with the PVDF pattern and FEVE coating to a quench station;
• and
• returning the coated metal substrate to a coiled configuration at the end of the flexographic coil coating line.