Tokyo, June 13, 2023, Dai Nippon Printing Co., Ltd. (DNP) has increased the number of wide-range coating devices suitable for the manufacture of high function optical film with a maximum width of 2,500 mm. The device has been added at the Mihara plant in Hiroshima prefecture in response to the ongoing shift to large screen televisions. 

In this latest development, we have introduced a new coating device capable of accommodating a 2,500 mm width as a second manufacturing line. As a result, the production capacity, on an area basis, has increased by more than 15%. This will boost the productivity of film for 65-inch large-screen TVs, with horizontal and vertical dimensions of 1436.4 mm x 809.0 mm. Due to this upfront investment, we will be in a position to rapidly respond to the growing demand for optical film for large displays, which is expected to expand. 

Image of Mihara Plant, where new wide coating device has been added

Strengthening High Function Optical Film Manufacturing Line

In line with the shift to large screen televisions in recent years, we are seeing increased demand for the large scaling of various components for displays, including panels, polarizing plates and film. According to the UK based market research company Omdia, the combined area of TVs and PC monitors is expected to increase at a compound annual growth rate (CAGR) of 5% from 2022 to 2026, and 4% from 2022 to 2029¹. In addition, as large 65-inch TVs become the mainstream, manufacturers of panels and polarizing plates in China are boosting production lines to stay abreast of such large-scaling, and in order to accommodate improvements in production efficiency. This had fed into a growing need for high function optical films for TVs that support 2,500 mm widths.

In response to these trends, in 2018 DNP led the world by introducing a coating device for 2,500 mm widths, which allowed for efficient extraction of film for 65-inch displays from produced optical film² into the production of protective optical films for polarizing plates. In order to further leverage this superiority, it was decided to add a new wide coating device at our Mihara plant.

Image of wide-width line

At the same time, the newly added wide-width coating equipment is designed to be able to coat two layers at the same time. As displays become more sophisticated and diversified in the future, multi-layered coatings will become necessary, and we will continue to meet the demand for Anti-glare-Low Reflection (AG-LR) film and Low Reflection (LR) film.

Image of LR product effect; comparison of conventional AG film (left) and AG-LR film (right)

Configuration diagram of LCD panel

Features of New High Function Optical Film Manufacturing Line

• The 2,500 mm width film produced on the new line makes it possible to efficiently manufacture high function optical film for 65-inch displays that are seeing increased demand on a global basis. 
• The new line has been designed for the productivity of the multi-layer coating that is important in order for improving the anti-reflective function and performance of high function optical film.
• The additional coating equipment is expected to reduce CO₂ emissions by 30% annually compared to currently used devices, through the introduction of new technology that reduces power consumption and via production process innovations.
• Capital expenditure for the new line is expected to be approximately 13.0 billion yen. 

Going forward

DNP plans to commence mass production with the new line from the first half of FY 2025. We will expand provision of high function optical film for displays to polarizer makers that produce around the world, beginning mainly with China, aiming for sales of 110 billion yen per year in FY 2026. DNP also holds a large number of patents for high function optical films in Japan and overseas, and we will take maximum advantage of our intellectual assets to meet the ever-growing demand for high-performance products.

1 Source: Display Long-Term Demand Forecast Tracker - 4Q22, Omdia.

2 Source: 2022 Current status and future outlook for display-related markets. Fuji Chimera Research Institute, Inc., 2022 Results

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