Coating and Laminating
Moisture Measurement Improves Manufacturing Quality in Coating and Lamination Processes
By Sarah Hammond, marketing manager, MoistTech
he moisture content in a product can have serious eff ects on its fi nal quality. Controlling and adjusting the moisture content throughout the coating and lamination process can eliminate many common manufacturing issues. While laboratory and other manual methods have been used for years, new automated moisture measurement and control systems can play an important role in improving product quality monitoring, increasing plant effi ciency and lowering energy costs.
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MOISTURE MEASUREMENT IN COATING AND LAMINATION
Coating and lamination are two distinct processes used to enhance and protect materials, particularly in print, graphics and textile industries. These processes play a crucial role in manufacturing, with moisture content signifi cantly aff ecting the quality and effi ciency of production. Moisture control is critical in both coating and lamination processes, as it can signifi cantly impact the fi nal product quality. In coating applications, maintaining appropriate moisture levels ensures that coatings adhere optimally to surfaces, which is essential for the longevity and eff ectiveness of the coating. Additionally, controlling moisture helps maintain the desired consistency and viscosity of coating materials, allowing for smooth and even application. Eff ective moisture measurement and management can prevent a range of quality issues in coated products, including blistering, peeling and poor fi nish quality. By implementing precise moisture control techniques, manufacturers can signifi cantly enhance the overall quality and durability of their coated products. Moisture control plays a vital role in lamination processes as well. First, it prevents excess moisture from causing delamination or poor bonding between layers, which can compromise the integrity of the laminated material. Second, maintaining appropriate
moisture levels ensures the strength and durability of laminated products, enhancing their longevity and performance. Lastly, accurate moisture measurement allows for the optimisation of the lamination process, leading to reduced waste and improved energy effi ciency.
MOISTURE MEASUREMENT TECHNOLOGIES There are several available methods for moisture measurement in industrial manufacturing settings, including visual inspection, manual testing, oven weight loss and moisture sensors. Manufacturers who rely on simple “guesstimates” based on sight or feel determined in a visual inspection cannot provide the necessary consistency or quality. Conducting manual testing by taking samples and bringing them to a laboratory for analysis adds considerable time to the entire process chain. Another possibility is the traditional oven weight loss moisture method, also known as the drying oven method or loss-on-drying (LOD) method. This method measures the moisture content of a sample by weighing it before and after heating it in an oven. While useful, this technique may end up burning off more than just moisture; it can burn off protein inside food or melt PVC inside a pellet. A more robust technology is the use of moisture sensors.
UNDER THE HOOD OF NEAR-INFRARED (NIR) TECHNOLOGY
Insensitive to material variations such as particle size, material height and colour, the MoistTech NIR technology provides continuous, reliable readings with zero maintenance. There is a one-time calibration with a non-drift optical design allowing operational personnel to confi dently make immediate process adjustments based on real-time measurements. Online sensors are mounted in diff erent locations depending upon the application, including on a belt, screw conveyor, chute, roller, chain, drag and elevator conveyors, cyclones, bins, before/after dryer, webs, pipelines and pneumatic conveyors. Sensors are installed about 4-16 inches from the product using a bracket on the back or top of the sensor. Sensor units are standalone and require no software or external output device. Display options are available but are not required for operation.
In addition to moisture, the sensors can measure coating weight, sheet and fi lm thickness, oil, protein, temperature and other elements that absorb NIR. Accuracy and repeatability is in the +/- 0.01 percent to 0.1 percent range, depending on the application.
Figure 1: MoistTech IR-3000 Series Moisture Sensor precisely measures the moisture content in vinyl coating
MOISTURE CONTROL AND QUALITY Moisture control in the coating and lamination process is an important issue with a signifi cant eff ect on quality and costs. Changing regulations and standards require monitoring and recording of moisture content for quality. In addition, global supply chain disruptions require tighter quality control and fi nding ways to ensure no waste/low waste. Using moisture measurement technology is an important way of meeting these goals.
12
March 2025
www.convertermag.com
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