Inline Color Measurement for the Paper, Textile, Plastics, Coil Coating, and Glass Industries
X-Rite’s inline color measurement solutions enable manufacturers in a variety of industries to evaluate color accuracy and consistency throughout production and track ISO compliance. Inline systems monitor color while the product is being made and alert operators if it begins to move out-of-spec so corrections can be made before the product is wasted.
The ERX145 spectrophotometer mounted on a traversing beam is automatically measuring the left, middle and right side of this sheet during production.
Each X-Rite inline color measurement system uses a non-contact spectrophotometer and ESWin software. Although many devices also work as standalone laboratory units, a system may include a moving frame or robotic arm to position the spectrophotometer over the line. Depending on application and needs, X-Rite’s inline solutions can communicate with process control systems to provide color measurement data and dye pump controls for real time closed loop color corrections. A system may also receive signals about events such as reel/sheet changes, machine stops or meter counts. Networked data allows manufacturers to share color standards and measurements among systems and at different locations.
Today we’ll look at how industries such as paper, textiles, plastics, glass and automotive are using X-Rite’s inline measurement solutions.
Paper Industry
To keep color and brightness constant throughout production, X-Rite’s inline paper color measurement systems span the entire process, from laboratory measurement to pulp, wet sheet, and measurement before reel up. The ColorXRA 45 (pulp color) or ColorXRA 45 Pulp (pulp brightness) spectrophotometer is mounted in a stainless steel box to measure color inline, while ESWin Closed Loop Color Control software records the quality of the run and alerts the operator of any deviation.
For laminated paper, a measurement on the wet paper is used before drying because the wet paper has a good correlation to the finished product, especially when the paper will be laminated on wood.
The most common measurement point in paper manufacturing is just before reel up, when the finished product is measured and compared to the lab results. If there is any color deviation from the standard, automatic closed loop color control will keep the color constant, plus help shorten startup and transmission times by approximately 50%.
This system includes inline measurement just before reel up to measure the color, opacity and content of optical brighteners on white or colored paper.
An inline system provides control for all paper and board types, including infinite layer color, opacity, and whiteness/brightness, and can be installed on any machine and easily connected to a DCS-system. The complete installation typically takes two to three days, with only two hours of machine downtime.
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Coil Coating
The color and gloss of coil coated products must be uniform across the length and width of each coil and conform to precise standards. Achieving this perfection requires accurate measurements in both the laboratory and during production, which can be especially challenging for projects containing different batches with various color adjustments. With X-Rite’s coil coating color measurement system, the ERX145 non-contact spectrophotometer is mounted on a traversing beam to automatically measure left, middle and right side. With a 30mm aperture, wavelength interval of 330 nm to 730 nm, and optical resolution of 1 nm, it offers excellent inter-instrument agreement and monitors temperature to identify thermochromaticity. To measure gloss, the GlossFlash 6060 spectrophotometer can be mounted alongside it.
Plastics Industry
Reflectance Measurement System
Color is becoming increasingly more important in plastics, and in both the automotive and furniture industries, tolerances continue to get tighter. An inline system can keep color on target, shorten transition times, and help operators react to color changes faster. With X-Rite’s reflectance measurement system, the ColorXRA 45 or ERX130 spectro is mounted above the web at a distance of 10 or 300 mm on a customized measurement frame. ESWin software controls the instrument and displays the measurements as a trend diagram for operators to monitor.
Inline Plastic Pellet Measurement System
Synthetic pellets must adhere to rigid tolerances and remain consistent throughout production. Instead of correlating pellet color deviation to the extruded plaque, X-Rite offers a way to measure directly during each run to detect issues earlier and reduce waste batches. The ERX130 system is usually installed above the separation sieve behind the granulator. Since it measures color continuously, issues can be reported to the machine operator when there is still time to make corrections.
Closed loop color control also enables manufacturers to use more recycled materials. KraussMaffei has designed a system that uses the ERX130 non-contact inline reflectance spectrophotometer to monitor color variations and directly adjust the precise color setpoint to compensate for minor deviations in production. This gives compound processors high reproducibility, even when processing input materials of varying color spectrum. In addition, the system helps get to precise color quickly when restarting the compounding process after a stop or color change, reducing the amount of start-up scrap and rejected materials for a more sustainable workflow.
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Inline Transparent Film Measurement System
For transparent films, color, visual light transmission and haze are extremely important and must be monitored throughout the production run. X-Rite’s inline transmission measurement system can help operators continuously monitor and correct even slight changes immediately. The ERX55 spectrophotometer is mounted in a C-frame on a linear track on the production machine. ESWin software controls the instrument, the measurements and the movement of the linear track. The color values, correlated haze and light transmission are displayed on the screen as a trend diagram to keep operators up to date.
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Glass Industry
Inline Glass Color Measurement System
Multiple silver layers on glass panes add functionality to architectural fronts and are state of the art in architectural design. Low-E glass or solar protection is used all over the world to save costs for heating or cooling houses. However, glass is a non-scattering product, which makes it a challenge to measure. X-Rite’s inline glass color measurement system uses a non-contact spectrophotometer to measure the production of non-scattering samples, like glass panes, directly on the production machine. The ColorXRA G3 illuminates the pane with a certain angle and measures the reflected light at the other side in the mirror gloss; allowing even functional layers, like low-E or solar protection, to be measured and quantified. The spectral curve, which is measured and displayed, provides detailed information about the reflectance from 330 up to 1000 nm. Transmission can also be measured.
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Textile Industry
Inline Carpet Color Measurement System
Any inconsistency in carpet color will very noticeable after installation. X-Rite’s inline carpet measurement system delivers continuous color measurement and quality reporting for production and laboratory measurements. The inline system can be used as a stand-alone unit or with a traversing beam for side-to-side monitoring. Color deviations can be detected and visualized in machine and cross direction to proof the quality of the produced goods. Runs can be qualified and sorted in different qualities to ensure a homogenous appearance within one shipment.
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Inline Denim Yarn Color Measurement System
Denim yarn must be on-color to ensure a harmonious finished garment. An inline color control solution measures wet and dry yarn color after dyeing to identify deviations so yarn can be sorted by shade for shipment. X-Rite solutions capture stable readings and report color data through QC software so operators can take countermeasures and track ISO compliance for bath dyeing, rope dying, and final quality control.
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Laboratory EN471 High-Visibility Clothing Color Measurement System
The color of high visibility warning clothing needs to be controlled not only during production, but also after washing. To secure the visibility of the people wearing that clothing, the color must be in within tolerance for the DIN EN471 specification. Because of the fluorescent colors, the physical illumination must be adjusted to CIE D65 not only in the visible range, but also in the UV area below 400 nm. By measuring UV included and excluded, the built-in Xenon flash lamp of the ColorXRA 45 Lab spectrophotometer is adjusted to the CIE D65 standard.
