Achieving Color Consistency and Quality in Coil Coating

The coil coating industry holds immense potential and promises a bright future. The global market for coil coatings showcases a positive trajectory, recording a value of USD 5.0 Billion in 2022 and is projected to grow to USD 6.8 Billion by 2030. However, it is crucial to acknowledge that the coil coating process itself is complex, requiring specialized equipment, skilled operators, and strict quality control measures to ensure consistent and reliable coating application. It would be unfortunate for inconsistent color applications to undermine this thriving market.

In response to this challenge, X-Rite has pioneered a comprehensive solution that comprises five essential steps to control color throughout the coil coating process effectively. This solution integrates state-of-the-art technologies, including the revolutionary ERX145 Inline Spectrophotometer and the cutting-edge GlossFlash 6060 Gloss Meter. This enables manufacturers to achieve precise color measurement and gloss assessment at each stage, from the laboratory to production and final quality control.

Perhaps the most significant advantage of X-Rite's solution is the seamless execution of these processes, eliminating the need to pause or reduce the speed of the production line. This feature is particularly beneficial for coil coaters who frequently deal with tight deadlines. With this solution, they no longer have to grapple with the challenge of sacrificing accuracy in order to meet demanding production schedules.

In this article, we will delve into the crucial steps involved in the Coil Coating Process, highlighting the associated challenges, and explore how X-Rite's five-step approach and innovative solutions play a pivotal role in attaining color consistency and quality in coil coating.

Key Steps in the Coil Coating Process

The complexity of the process requires specialized equipment, skilled operators, and strict quality control measures to ensure consistent and reliable coating application.

The challenge is compounded by the sheer speed with which coil strips move, reaching up to 700 fpm, which is equivalent to 200 m/min. Each step is critical to producing superior color quality and coating consistency. Here is how it works:

• First, the coil strip is unwound and subjected to meticulous cleaning and brushing to eliminate any contaminants or impurities that may hinder proper coating adhesion.
• Next, a chemical treatment is carefully applied, and the strip is thoroughly dried to create an optimal surface for coating application.
• Subsequently, a primer, either on one or both sides of the strip, is skilfully applied. This primer serves as a foundation, enhancing the adhesion and durability of the subsequent coating layers.
• Once the primer is in place, the strip is sent through a precisely controlled oven for curing.
• After completion, the cured strip is delicately removed from the oven and allowed to cool.
• The subsequent step involves the application of the desired coating on one or both sides of the strip. This coating, meticulously chosen for its desired properties and aesthetic appeal, is applied with precision and expertise.
• Following the coating application, the strip undergoes a second round of curing in an oven, ensuring proper bonding and enhancing the coating's overall durability.
• Once the second curing process is completed, the coated strip is carefully cooled.
• Finally, the coated coil is skilfully rewound, preparing it for further processing or shipment as a finished product.

As you can see, many steps are involved in the process, and numerous challenges can arise that may jeopardize the final result. Unfortunately, many coil coaters have tight deadlines and strict quotas to meet. In the event of an issue, they are confronted with the dilemma of compromising accuracy to meet demanding production schedules.

Challenges Impacting Colour Quality in Coil Coating

?Factors such as improper cleaning and brushing can lead to inadequate surface preparation, hampering coating adhesion and producing subpar quality. Inconsistent chemical treatment or incomplete drying may cause variations in surface properties, leading to uneven coating application. Inaccurate primer application or curing can compromise the foundation of the coating, affecting its adhesion and long-term performance.

Moreover, deviations in the coating application process, such as variations in thickness or uneven distribution, can adversely impact the finished product's visual appearance and protective properties. Issues during the curing and cooling stages can also disrupt the coating's integrity and compromise its overall quality.

In essence, the coil coating process demands meticulous attention at every step to ensure superior results. Deviations or errors can significantly affect the final product's quality, durability, and aesthetic appeal. Hence, it is crucial to implement stringent quality control measures, employ skilled operators, and utilize advanced technologies to mitigate potential pitfalls and uphold the highest standards of coil coating excellence.

X-Rite's Five-Step Solution

X-Rite has developed a comprehensive solution consisting of five steps to effectively control color throughout the coil coating process. This solution incorporates advanced technologies such as the ERX145 Inline Spectrophotometer, along with the GlossFlash 6060 Gloss Meter, enabling manufacturers to achieve precise color measurement and gloss assessment at each stage, from the laboratory to production and final quality control.

Our five-step process is as follows:

1. The process begins in the laboratory, where a specialized laboratory spectrophotometer equipped with a heating table assists paint suppliers in defining color standards for coil coating. The color standard is measured under different temperature conditions, providing valuable insights into how temperature changes may affect color during the production process.
2. Once the color standard is established, it is shared with all relevant stakeholders involved in the workflow, including the paint supplier, production control booth workstations, the color coating line, and client sites. This ensures everyone has access to the same accurate color data, promoting consistency and minimizing potential discrepancies.
3. As the coil coating process commences, X-Rite systems continuously evaluate the color quality across each coil's entire length and width. A traversing beam holds and moves the inline spectrophotometer horizontally, allowing for color measurement while the coil is in motion. This setup ensures a safe distance between the device and the coil, even in challenging operating conditions, and enables accurate measurement of uneven coil surfaces.
4. Real-time results are shared throughout the network, enabling all stakeholders to monitor color quality and consistency. In the event that color tolerances are exceeded, the system generates graphics and alerts, promptly notifying users and preventing costly mistakes resulting from color deviations.
5. X-Rite's Coil Coating Inline Color Measurement System even provides comprehensive documentation based on international standards, ensuring the program's integrity and customer satisfaction. These color quality records serve as a valuable reference, capturing crucial information and supporting traceability and compliance requirements.

As already touched upon, the greatest advantage lies in the fact that all of these processes occur seamlessly without the need to halt or decelerate the production line. This significant development ensures that coil coaters no longer need to make compromises when it comes to color accuracy.

By implementing X-Rite's advanced technology and following this five-step solution, manufacturers can effectively control color throughout the coil coating process. This enables them to achieve consistent and accurate color results, enhance product quality, reduce waste, and ultimately deliver superior products to their customers.

Take a moment to explore our website for further details, or delve into our comprehensive white paper to discover how X-Rite solutions streamline and simplify the coil coating process.