X-Rite’s inline color measurement solutions monitor color accuracy during production. If color begins to move out-of-spec, the system alerts operators to make corrections before any product is wasted. Coil coating is one area where inline color measurement is very effective for achieving the most cost benefit.
The coil coating process has been around for more than 30 years, allowing companies to produce durable and attractive products. However, to achieve cost benefit, the focus must be on efficiency, effectiveness, quality, and accuracy. Coil coating gives manufacturers a way to paint the metal while it is still in sheet form. This is important, because trying to paint metal after it has been formed into parts makes it difficult to achieve a uniform coating.
The coil coating process is fast, and mistakes must be caught immediately to avoid expensive waste. X-Rite’s coil coating inline color measurement system incorporates the ERX145 inline spectrophotometer and the GlossFlash 6060 inline gloss meter to evaluate color and gloss in real time. If color or gloss start to shift, the press operator can make the necessary interventions immediately to ensure the run remains within the required specifications.
Today we will explain how an inline system can contribute to quality and precision in coil coating.
Coil Coating Fluctuations Can Cause Color Errors
Many parameters influence the color in coil coating. Starting with the ink itself, through the contact pressure of the applicator rollers, the web speed to the oven temperature, and more. What can go wrong? A lot.
Heat can affect the constant coloring. When coating, the color is baked twice in an oven. The time spent in the oven, together with variations in oven temperature, can affect the color.
The gloss will affect the appearance of the color, making it look lighter or darker.
Variations in the paint thickness will also affect the color. The coating must be consistent throughout the entire process to achieve uniformity, both in the machine direction and in the transverse profile.
Add to that the fast pace of the production line, and you can see why it’s a challenge for coil coaters to meet vigorous color standards.
A Five Step Solution for Controlling Color
X-Rite has developed an inline system to monitor the entire coil coating process. Using the ERX145 together with the GlossFlash 6060 Gloss Meter, manufacturers can measure color and gloss with a high degree of accuracy during each step – in the lab, on the production line, and through final quality control reporting and documentation.
It starts in the lab, where a laboratory spectrophotometer with a heating table helps the paint supplier formulate and define the coil coating color standards. The temperature is also measured to determine how the applied color behaves at different temperatures.
The defined color standard is communicated to all parties involved in the workflow so the coating manufacturer, laboratory technicians, production staff at the coating line, and customers can all access the same color data.
Once the coil coating process begins, the X-Rite inline system provides continuous color quality assessment across the entire length and width of the coiled metal strip (coil). A cross beam serves as a suspension and moves the inline spectrophotometer across the web to measure the cross profile. The measurements are taken at a distance of 55 mm. When a seam is made, the measuring system moves to the parking position next to the strip. Therefore, the device cannot be damaged even under the most difficult conditions.
Since the measurement results are communicated in real time, all users on the network can monitor color quality and consistency. If a production tolerance is exceeded, graphics and warning messages are displayed before color deviations are out of tolerance, resulting in costly errors.
X-Rite’s coil coating inline color measurement system even provides complete documentation in the form of color quality records based on international standards to ensure the integrity of the program and customer satisfaction.
Best of all, everything happens without having to stop or slow down the production line, so coil coaters never have to choose between accuracy and production schedules.
Learn More about X-Rite Inline Solutions
Check out our white paper to learn more about how X-Rite solutions make the coil coating process faster and easier. If you have questions, our Color Experts are here to help! Fill out the form to get in touch.
