Paper coating apparatus with multiple hot wax applicators and associated methods

A paper coating apparatus for applying a wax coating to a continuous paper sheet advancing along a path of travel, the paper coating apparatus comprising:

• a frame;
• an entry guide roll and an exit guide roll both carried by said frame in horizontal alignment along the path of travel;
• at least one hot wax reservoir carried by said frame;
• and
• a plurality of independently controllable hot wax applicators carried by said frame in horizontal alignment in series between said entry and exit guide rolls, each independently controllable hot wax applicator comprising
• a press roll,
• an engraved applicator roll below said press roll so that the continuous paper sheet is therebetween, said engraved applicator roll extending into said at least one hot wax reservoir to pick up hot wax therefrom,
• a doctor blade adjacent said engraved applicator roll to control a thickness of hot wax thereon,
• at least one selectively operable positioner to relatively move said press and engraved applicator rolls between active and idle positions, said press and engraved applicator rolls contacting the continuous paper sheet therebetween and applying hot wax thereto when in the active position, and at least said engraved applicator roll not contacting the continuous paper sheet when in the idle position;
• said entry and exit guide rolls defining an unobstructed linear internal path of travel for the continuous paper sheet through said plurality of independently controllable hot wax applicators when each is in the idle position.

A method of making a paper coating apparatus for applying a wax coating to a continuous paper sheet advancing along a path of travel, the method comprising:

• coupling an entry guide roll and an exit guide roll to a frame and along the path of travel;
• coupling at least one hot wax reservoir to the frame;
• and
• coupling a plurality of independently controllable hot wax applicators to the frame between the entry and exit guide rolls, each independently controllable hot wax applicator comprising
• a press roll,
• an engraved applicator roll opposite the press roll so that the continuous paper sheet is therebetween, the engraved applicator roll extending into the at least one hot wax reservoir to pick up hot wax therefrom,
• a doctor blade adjacent the engraved applicator roll to control a thickness of hot wax thereon,
• at least one selectively operable positioner to relatively move the press and engraved applicator rolls between active and idle positions, the press and engraved applicator rolls contacting the continuous paper sheet therebetween and applying hot wax thereto when in the active position, and at least the engraved applicator roll not contacting the continuous paper sheet when in the idle position.