WET PAINT THICKNESS MEASUREMENT
WFM1 is the only on line film thickness instrument in the world that sets up the coater to the perfect film build before production commences. This delivers unique savings by eliminating test strips. All product meets specification from the start of every new production order. WFM1 doesn’t just measure on-line wet film build, but delivers dry film thickness on both edges of the strip for perfect edge to edge balance. The savings this delivers are unprecedented and typically well above $ 1,000,000 per year. WFM1 is reliable and calibration free. It’s easy to use requiring just a minute of set-up time when the coater roll is swapped over.
How Do the Savings Add Up?
Test strips will rob you of 1000 hours of production time every year. Imagine having another 10% of production capacity at minimal cost.
Test strips rob you of 75,000 lineal meters of substrate. That’s worth $250,000 pa
Slashing the paint thickness specification from +/- 1.2 to +/- 0.6 microns (+/- 0.05to +/-0.025 mils). Combine that with perfect edge to edge film thickness balance gives realistic paint savings 5%. $200,000 savings pa are realistic.
If you’re not using test strips then you’re probably using the wet film wheel. That wastes 30,000 meters of substrate valued at around $300,000 pa. Whichever way you look at it, WFM1 delivers huge savings, great product quality, and one of the shortest payback periods of any capital investment you can envisage for your coil coating line.
Above estimates based on a typical 100ktpa production line.
• Measures on-line wet paint thickness on the coater
• The correct film thickness is set up before painting commences
• Displays wet and dry film thickness on the strip throughout production
• Total film thickness control from the first to the last meter of every coil
• Perfect film thickness control every day, every week, every year
• Wet film is converted to dry film thickness using PVS1 paint volume solids data
• It’s good for all paint types in forward and reverse coating mode
• Requires the transfer efficiency for the coater which is determined during commissioning
• Two WFM1 units are needed if you have two topcoat coaters
• Unique patented direct measurement principle ensures unparalleled accuracy
• Measures film thickness to +/- 0.2 micrometers
• System is proven and in use in California and Europe producing quality architectural and automotive parts for major European car manufacturers including Mercedes and BMW
• Local service and support is based in Europe (Germany), USA, Canada, India, South East Asia, South America, and Australia
Commercial Benefits – Rapid Payback on all Coil Lines
• Gain 10% of line capacity by confidently eliminating 90% of test strips. The benefit is valued at above $ 1million per year. Test strips typically take 500 hours of production time which equates to 10,000 tpa of line capacity within existing shifts
• Additionally, save over $250,000 annually in steel strip used for test strips. For a 100,000 tpa line 20 meters of test strips every 25 tonnes (a conservative estimate for most coil lines) is 130 tonnes of lost steel coil every year.
• If you don’t use test strips then the critical first 200 to 300 meters of each new production run will be prime with perfect thickness every time; there is no need to wait for the product to be cured in the finish oven before testing – this significantly improves paintline yield. Savings include the aluminium or steel substrate, paint, labour, power, production time, line capacity, off colour defect, and claims
• Eliminate using the wet film wheel for film build checks. For a 100,000 tpa paint line 5 meters of wet film wheel track marks every 20 tonnes equals 90 tonnes of lost product per year
• Eliminate all film thickness related defects including a big chunk of off colour
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.