DFM-Ultra On-Line Dry Film Thickness Instrument
DFM-Ultra delivers the best value proposition of any Wolf Innovation product. It’s versatile and forms a solid foundation for future upgrades with other Wolf Innovation products, but from day one it will deliver massive savings and ultimate coated product quality.
DFM-Ultra is such a good deal it should be on every coil coating line.
DFM-Ultra 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-Ultra measures at a fixed location across the strip we show you how to balance your coater to deliver paint savings of around 4%.
DFM-Ultra is a perfect partner with WFM1. It tunes WFM1 for unusual production conditions including heavy gauge product where paint transfer efficiency is prone to variability.
DFM-Ultra can be upgraded in the future to full DFM1 capability, so it’s the perfect way to get going with Wolf Innovation products.
DFM-Ultra can be paired withWFM1 on the primer coater delivering on line primer and topcoat thickness along every coil.
DFM-Ultra 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-Ultra 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-Ultra 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 off colour product.
• Suitable for line speeds up to 200 mpm
• Can be easily integrated with WFM products for separate primer thickness
• Can be integrated with coater control devices for closed loop control
• 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-Ultra to get immediate paint savings and guarantee quality. In fact DFM-Ultra is so cost effective, every paint line should have this – regardless. A great advantage of DFM-Ultra is that it can easily be upgraded to a full DFM1 at any time in the future. Having started with DFM-Ultra 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-Ultra talk during production and compare notes. DFM-Ultra 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-Ultra.
That combination – WFM1/PVS1/DFM-Ultra 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.
ADD A PHAETON
Now you’ve got your topcoat fully in control. That’s where the biggest savings are. You can now focus on primers and backers.
I personally like the idea of adding a Phaeton lab thickness instrument at this stage of the CCS1 build up. It’s unique in that in just 2 seconds you get hundreds of measurements from edge to edge – a full profile of thickness results providing unprecedented information on the condition of your coater roll and the coater set-up. Phaeton should be located just near the exit shear of the paint line. Cut the sample and measure the profile in seconds. Ideally the monitor showing the sample results is located at the coater room with a second monitor in the quality control lab. Measure the topside, then flip over the sample and measure the bottom side. Generate a sample of primed strip at the leading edge of each coil so that you can measure primer thickness quickly and efficiently, and again, on both sides of the strip.
So when should you add the Phaeton – about 2 months after installing WFM1/PVS1. Just use the savings in hand – it won’t cost anything in real terms.