The Role of Inline Spectrophotometry in Color Control in Coil Coating

Coated steel and aluminium panels play a crucial role in various industries, especially in construction and commodities, where their durability and appearance are key factors. Consistent color quality is vital as it directly impacts how consumers perceive and accept these products.?

Traditional methods of color measurement present significant challenges, particularly in providing timely feedback to operators during production. While laboratory equipment offers precise data for quality control in the coil coating, its retrospective nature requires samples to be analysed after production. This lack of real-time insight into color consistency hampers operators' ability to adjust production processes proactively.

The Need for Inline Color Measurement Solutions

To overcome these challenges, there is a pressing need for inline color measurement solutions that can seamlessly integrate into production lines. These systems would provide continuous, real-time feedback on color accuracy, enabling operators to make immediate adjustments as necessary. By bridging the gap between laboratory analysis and real-time production conditions, inline color measurement not only improves efficiency but also ensures that coated panels consistently meet strict color standards throughout manufacturing.

This leads us to X-Rite's groundbreaking ERX145 spectrophotometer. The ERX145 represents a significant advancement in addressing the limitations of traditional color measurement methods specifically tailored for the coil coating industry.

X-Rite's ERX145 Spectrophotometer

The ERX145 provides real-time color analysis mounted on a traversing beam, empowering operators with immediate insights into color variations and enabling prompt adjustments. By seamlessly integrating into the production system, it not only improves operational efficiency but also supports automation.

This device is particularly effective in mitigating costly production line color errors, especially in environments requiring frequent color changes. When coupled with ESWin QC software, it transforms into a comprehensive inline quality control system. This setup alerts operators to color shifts in real time, facilitating swift corrective actions without halting production.

Key specifications include:

• Color Reproducibility: ≤0.03 dL*, da*, db*
• Inter-Instrument Agreement: ≤0.3 dL*, da*, db*
• Measurement Geometry: 45°a:0°?

The ERX145 Inline, utilizing a 45°a:0° measurement geometry, can be securely mounted on a traversing beam above or/and below the production line. This positioning allows it to detect color deviations early, preventing potential material wastage. When paired with ESWin QC? software, it not only ensures excellent correlation with the laboratory-grade spectrophotometer ERX145 equipped with a thermochromism heating table but also adheres to international standards for objective evaluation, safeguarding the accuracy of inline measurement processes.

Installed strategically behind the water quench to capture measurements while the product is still hot, the ERX145 incorporates a built-in pyrometer. This pyrometer accurately measures the strip's temperature, adjusting color readings to room temperature through collaboration with the ESWin QC software. For comprehensive evaluation of color and gloss across the coil's dimensions, the ERX145 can be complemented by the GlossFlash 6060 if needed. In scenarios requiring dual-sided color assessment, a second ERX145 Inline can be positioned beneath the roll.

Additional features include:

• Short-term Stability and Long-Term Accuracy: It utilizes real dual-beam measurement and automatic wavelength calibration, minimizing the need for frequent external recalibration.
• Operational Durability: Designed to withstand challenging production environments such as dust-laden settings, ensuring consistent measurement accuracy.
• Precision in Measurement: Positioned at a distance of 60mm (2.4") with a 30mm measurement spot, it minimizes discrepancies between inline and laboratory measurements.?

Conclusion

X-Rite's ERX145 spectrophotometer emerges as a pivotal tool in modern coil coating operations, effectively enhancing quality control through real-time, integrated color management capabilities.