New measurement technology - a boon to paint producers and users

New measurement technology ­ a boon to paint producers and users

Keywords Grant Instruments, Measurement, Paints

While paint manufacture is a precise science, many process variables can affect the surface quality ultimately achieved, including the rate of cure. Recognising this, Kemira Coatings offers application support to all its customers seeking to produce a consistently high-quality finish while controlling energy costs.

As part of its customer service commitment, Kemira routinely checks its customers' conveyor ovens and curing facilities. The company's applications engineers are also called out from time to time to troubleshoot particular problems.

Energy efficiency and quality requirements are inextricably linked in the finishing process. Poor productivity, and quality problems such as inaccurate colour, insufficient gloss or adhesion, are as often caused by using too much energy as too little. A high-quality outcome goes hand-in-hand with energy efficiency.

Data acquisition is an essential part of the process optimisation service. Currently using conventional data logging technology, Kemira has recently investigated a new system from Grant Instruments of Cambridge which has the potential to provide a precise solution to the problem of producing a quality finish while minimising energy usage (Plate 1).

"We are at present using standard thermocouple datalogging systems for routine testing and troubleshooting", comments Kemira applications engineer Martin Carter, "but there are drawbacks to traditional measurement technology."

With its existing datalogging equipment Kemira sets up air and surface temperature measurement probes and records readings in a memory pack for computer analysis. "We can set up the equipment to collect data and then find that the line has come to a halt for some reason and battery power is exhausted to no purpose", Martin Carter continues.

 Plate 1 Grant Instruments' RF400 system

"Even assuming we collect all the data we require, there is a delay while we download to a computer,either on site or back at West Bromwich, for analysis."

Midlands Electricity Powerline's recent Finishing Excellence '97 seminar was the showcase for Grant Instruments' new-generation oven datalogging system. The Squirrel RF400 system uses radio telemetry to transmit data collected by temperature sensors to a computer. Grant's Paintwise software allows fast analysis using advanced cure calculations. As a result, high-accuracy data on up to six measurement channels can be presented on screen in real time, in either a graphical or tabular format, enabling fast-response control over finishing processes. Introduced to the RF400 at the seminar, Martin Carter welcomes this new development with enthusiasm: "The RF400 system appears to be exactly what the market has been waiting for. We will be able to provide our customers with advice on oven set-up on the spot. Customers using 'rule of thumb' techniques and intrigued by the idea of oven monitoring, as many are, will be even more excited by the idea of on-line monitoring.

"For the first time,manufacturers will be able to respond rapidly to fluctuations in the temperature profile resulting from variations in oven loading and substrate thickness."

Paintwise software features a "best cure" profile overlay capability which immediately highlights these fluctuations and enables the oven settings to be fine-tuned for a quality finish. "With realtime oven setting, users of the RF400 will be able to eliminate downtime for oven optimisation and dramatically reduce rework and scrap."

It follows that adherence to the "best cure" profile automatically guarantees energy efficiency. Martin Carter concludes: "For on-line measurement or for troubleshooting, engineers and technicians concerned with quality finishing cannot afford to ignore the potential this new technology offers for improved quality and reduced operating costs."

Grant Instruments can supply turnkey measurement solutions including the datalogger, sensors and software. The RF400 system is licence exempt in the UK.

Details from Grant Instruments (Cambridge) Limited. Tel: +44 (0)1763 262600; Fax: +44 (0)1763 262410.