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Analyzing the coat-weight of your coating is a critical part of maintaining an efficient and effective operation. When you utilize our NIR meters to provide the necessary data, you cut down on costly mistakes as well as unnecessary labor all while increasing the quality of your final product and minimizing product loss.
Coating thickness can be accurately measured and instantly displayed in any units appropriate to the application and necessary for your operation. Typical coating units that can be digitally displayed include:
These measurements are made by mounting a near infrared (NIR) sensor about 10 inches over the measured material and shining a one-inch diameter light onto the surface. The sensor is mounted just after the wet coating is applied. Coating techniques can be gravure, rotating wire-wound rod, stationary rod, spray or dip. The non-contact sensor measures coat weight or moisture by comparing energy at two NIR wavelengths, and it sends the signal to an alphanumeric display at the readout console.
This console also provides a sealed touch keypad for all calibration data entry including unlimited calibration tables, alarm set points, loss of coating or web alarms, PID control table, and 4-20ma or Ethernet output signals proportional to coat weight or moisture content. The Ethernet output signal is useful for recording or for closed loop control of process variables such as line speed, transfer roll revolution, gap pressure, or dryer temperature/dampener adjustments.
The coating analyzer is easily calibrated by securing just two raw signals that are proportional to two known coat weight samples. the first signal is simply read off the console display while holding an uncoated sample under the sensor’s light source. A second (higher) signal is read while the process is running at normal operation conditions producing target coat weights. This table, representing two calibration signals versus two known coat weights (zero and target coating), is entered into the readout console via the keypad and stored in two internal look-up-tables. The console MOISTURE key is then pressed to view direct coat weights or moisture content on the digital display.
Finna Sensors’ new Scanframe: Web-Profiling System gives our OMNIR on-line near infrared sensor the freedom to measure cross-directionally and see what’s happening across a paper or substrate with a coating being applied. Scanframe easily positions above your production line to help you:
The OMNIR sensor has the most advanced near infrared (NIR) data gathering and analytics on the market, providing real-time collection and analysis of moisture and coat weight. Specified product data is collected by shining a non-invasive light on the material substrate. The OMNIR sensor, calibrated for that specific material, interprets the returning light energy using an advanced photo detector, intuitive smart software and automation options.
The Scanframe system allows manufacturers in industries such as paper products, food and drug packaging to automate and move the non-contact, non-invasive OMNIR sensor to a preprogrammed or manually input pattern across up to 20 feet. This lets your operators see more of the line, and it allows for time-saving adjustments to control needs and output. Through sensor readings, the software generates powerful analytics to help guide manufacturing to find new efficiencies and cost savings in their moisture-sensitive and coat weight applications.
Scanframe is a mechanical scanning innovation designed to traverse the intelligent OMNIR sensor. Powered by a motor and gear system, the OMNIR smoothly glides across a robust aluminum I-beam (stainless steel option also available), positioning the OMNIR sensor either manually or to programmed measurement location points, for a non-contacting, continuous measure and output of robust moisture or coat weight data.
Controlled through a PLC computer, Scanframe easily integrates OMNIR sensor data in real time and delivers combined output of both sensor position and measurement value. Smart software visualizes results to help identify areas for improvement across a sheeted web. Scanframe includes its own control panel, smart software, and a motorized guidance system to position the OMNIR sensor and collect data as the sensor scans. It can be programmed to move at variable speeds and allows for adaptable motion patterns.
There are several instances where customers ask to capture a broad range of coat weight or moisture readings taken from across the web. Some webs will be applying a curtain coat to cover an entire sheet, while others will divide the profile of the moisture or coat weight readout into different zones across the web. This can be done across clear films too.
Scanframe changes the game for these operations with enhanced collection of OMNIR sensor data. The new information is used to control the cost of:
The more complex the manufacturing, the more power Scanframe gives the OMNIR sensor. Powerful new efficiencies can be realized in complex manufacturing processes that require multiple stages of coating at many different points.
A use-case example is the automated production of stickers. A sticker can be made with silicone coated paper and an adhesive that gets laminated to a base paper. The final sticker has a print on it and when you peel the sticker off, the printed coating transfers or releases from that silicone base, which is what allows it to stick to a surface. Get the moisture or coat weights wrong and the product won’t stick, or maybe won’t release at all.
In a multi-stage case like this, the process operator might want to measure the moisture of the base paper or depth of coating on the silicone liner before laminating. They might also want to look at re-moisturizing to ensure the sheet is laying completely flat, or the manufacturer might look to ensure their coatings are evenly applied. No matter the pain point, Scanframe and OMNIR deliver the robust data that these complex production processes require. This helps you to find efficiencies and savings across the line and produce the best possible product at the best possible cost.
If controlling your production costs, reducing waste, increasing production output, saving time and optimizing product quality is important to you, our Scanframe:Web-Profiling System is a smart scanning solution. Scanframe is ideally suited for both narrow and wide webs. It measures and optimizes cross-directional moisture addition — via steam, spray, or reverse-roll water application — by reintroducing moisture back into the sheet. It also measures coating weight to determine coating deposition thickness, whether the coating is water-based, UV adhesive, or hotmelt.
Scanframe is also designed with a dedicated maintenance “park” position that allows the sensor to be easily positioned off-sheet for roll changes on the line, web breaks, OMNIR calibration or maintenance. With Internet of Things (IOT) in mind, Scanframe and OMNIR are both designed to be connected for diagnostics and software upgrades through a simple internet connection.
Whatever your measurement needs, we can help you create the right, integrated solution to optimize your efficiency and increase your profits.
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