dfm-alpha

DFM-Alpha On-Line Dry Film Thickness Instrument with Closed Loop Control

DFM-Alpha – the final solution.

The first truly affective closed loop control system in the world.

DFM-Alpha delivers intelligent closed loop control (CLC). Best of all, you don’t need to make expensive capital cost changes to your coater to implement this instrument. Our DFM direct measurement technology accurately measures DFT. Our intelligent CLC approach uses advanced coating model algorithms to calculate the precise and usually small correction needed to hit target DFT. There is no homing in on the correct DFT value as would occur with a conventional PID control loop. DFM-Alpha is the final solution in automated coated product quality control.

DFM-Alpha has the only intelligent closed loop control system for coil coating.

DFM-Alpha delivers control to an average thickness variation of 0.2 micrometers down the length of each coil. The coating is held within a control band of +/- 0.5 micrometers. Whilst DFM-Alpha measures at a fixed location across the strip we show you how to balance your coater. The system automatically ensures delivery of maximum paint savings, typically better than around 4%.

DFM-Alpha is a perfect partner with WFM1. It verifies WFM1 and homes in on an even tighter control band.

DFM-Alpha can be paired with WFM1 delivering on line primer and topcoat thickness along every coil.

DFM-Alpha is fully automated and is extremely easy to use requiring almost no operator input. It’s calibration free delivering perfect compliance to your products quality specification across 98% of pigmented paint types.

  • DFM-Alpha and DFM1 deliver the highest precision of any on line film thickness instruments in the world
  • Fully automated measurements throughout every coil with no operator input
  • Fully calibrated for all paint types and substrates – excludes clear and rubber coats
  • DFM-Alpha provides a complete production record – tonnes painted, speed, stoppages
  • Uses a unique patented direct measurement principle for ultimate accuracy
  • Eliminate all film build related defects including a large portion of off-colour product.
  • Suitable for line speeds up to 200 mpm
  • Can be easily integrated with WFM1 for separate primer thickness
  • Records all actions and results in a perpetual database in CSV format

CCS1 COATING CONTROL SYSTEM

COMPLETE CONTROL OF PRIMER and TOPCOAT WET and DRY FILM BUILD

The Wolf Innovation suite of products deliver fabulous benefits but with so many choices they pose the question of what to install. So how do you decide what components logically fit together to deliver the best business outcome for your production line. Here you will find the logical combinations for complete quality assurance of all coating layers. The instrument packages are designed to deliver the best outcomes and the best business case to suit your needs.

BUILD IT UP ONE COMPONENT AT A TIME

One of the great things about this system is that you don’t need to buy it all right from the start.

There are two logical alternative starting points to build up CCS1. The choice between these is simply based on available capital. If its low then start with DFM-Alpha to get immediate paint savings and guarantee quality. In fact DFM-Alpha is so cost effective, every paint line should have this – regardless. Having started with DFM-Alpha the next logical step is to add WFM1 and PVS1. This addition adds the ability to set up the coater before production commences. WFM1 and DFM-Alpha talk during production and compare notes. DFM-Alpha will fine tune WFM1 for perfect monitoring of every coil from the very first metre.

The other great starting point is WFM1 with PVS1. Eliminate test strips, eliminate wet film wheel track marks, save paint, save steel and improve your lines yield. If you do test strips now the savings are likely to be well above $1,000,000 every year. Use your first month’s savings to add in DFM-Alpha.

That combination – WFM1/PVS1/DFM-Alpha is the foundation of CCS1. It’s the perfect basis from which to introduce closed loop control. It is a wonderfully automated easy to use system. Of course the operator will still have to do paint volume solids testing which takes a minute of his or her time at every paint change