Benefits of Measuring Your Hot Melt Coating Thickness Cross Direction Web Profile

Speeding up the start-up process, reducing scrap and rejected material, archiving data against claims and improving QC/QA are among the many benefits of measuring your hot melt thickness web profile with a NIR Transmitter and Guardian Scanning Profile System.

Whether you operate doctor blades, die bolts or other hot melt applicators, a uniform web profile is important to you and your customers.  Often times the system is started up and stopped while a sample is sent to the lab for analysis.  After receiving the results, the applicator is adjusted and started up only to be stopped for another sample and analysis to confirm correction.  Sometimes the adjustment over compensates and the process repeats itself.  With a web profiler, the machine can be adjusted while running and the results immediately seen on the hot melt profile display.  A trend chart and plot below illustrates the hot melt process in adjusting the applicator to meet a 1.4 mils target set point.  Red is alarm out of specification, yellow is alert getting out of specification and green is good at a set point of 1.4 +/- 0.1 mils hot melt thickness.

Hot Melt Trend Plot Table 102914

Hot Melt Trend Plot 102914

 

 

Hot Melt Measurements With Guardian Options

hot-melt-adhesivesHot Melt Measurements are typically measured with Near Infrared (NIR) transmitters that provide a digital display in engineering units, analog outputs and a digital interface.  The NIR non-contacting Hot Melt measurement is extremely accurate and stable with no regulatory requirements.  The measurement can be fixed point or scan across the web to provide a cross direction web profile.

The Guardian Web Profile System provides a Cross Direction profile on a large flat panel LCD in an economical and attractive enclosure. The Guardian is fully automated with product recipes for scan speed, zone average, and data logging digital outputs. This is a complete system with automatic web edge detection to provide the highest value performance to cost ratio. The system can supply CD Web Profiles and MD Trends for hot melt thickness, residual moisture and temperature. Multiple measurements can be displayed on a single large display screen.

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The Entry Level Profile System provides a simple and inexpensive automatic scanning frame with a 12” Operator Inteface (OI) for profile display and controls mounted on the frame end.  The Simple Cross Direction Scanning System with Digital Display allows for automatic scanning or jogging to fixed position for machine direction measurement and display on a 5.7” touch screen.

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Pack Expo Chicago Booth E-8362

Guardian Scanning Frame System :  Process Sensors Corp. announces a new economical introductory level Guardian CD Web Profile System for the Packaging, Tape and Label Markets. The New Guardian OI based system features a single frame with 12” Touch Screen Profile Display. The Guardian System can measure moisture, water based coat weight, film thickness and organic deposition on a wide variety of substrates including paper, film, foil, metal, non-wovens and more.

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Label Expo Chicago Booth 1828 September 7 – 9



Label Expo logo 071414Process Sensors Corp.  announces a new economical introductory level Guardian Cross Direction Web Profile System for the Tag, Tape and Label Markets.  Process Sensors Guardian System offers large central display consoles with remote work stations and displays for multiple scanners and multiple measurements down the line.

The New Guardian OI based system features a single frame with 12” Touch Screen Profile Display and will be introduced at the Label Expo 2014 in Chicago (Booth #1828).  Both Systems feature advanced diagnostics, automatic web edge detection and easy to operate menu recipes.  The Guardian System can measure moisture, water based coat weight, film thickness and organic deposition on a wide variety of substrates including paper, film, foil, metal, non-wovens and more.

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Choose Your Guardian!

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Guardian CD Web Profile System Options

Process Sensors Guardian Cross Direction Web Profile System can be as simple and inexpensive as an automatic scanning frame with 12” frame mounted Operator Interface (OI) for profile display and controls.

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The Guardian Profile System can also connect to a 19” Display at the Central Console or a 55” or larger display for multiple scanners and measurements integrated into a single distributed system.  The Guardian System can be operated manually or via a Human Machine Interface (HMI).

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Glue Pillow Moisture Application – MCT460 NIR Transmitter

H.B. Fuller Pillow Lab pic edit 051414In packaging, converting, assembly, bookbinding, nonwovens, footwear and many other markets, hot melt glues and adhesives offer a critical advantage: fast processing. Unlike water-based or solvent-based adhesives, hot melt adhesives do not require drying. Hot melts begin bonding almost immediately after application, as they cool down to their solidification point. This fast solidification is ideal for use on highly automated manufacturing lines that require rapid bond formation.  Glue pillow manufacturers report increasing demand as customers move from drums to returnable/recyclable containers.  While the moisture contained within the glue pillow is very low, problems occur when surface moisture on the pillow exterior accumulates during the manufacturing process prior to packaging for shipment.

The Near IR moisture transmitter is mounted 8-18” above the conveyor where it scans product only, with few gaps between pillows.  An angle wedge or diverter may be installed that insures constant glue pillow product under the transmitter without slowing the overall product flow.  The intention of measuring moisture on the glue pillow is not to determine absolute moisture but to determine when the surface moisture is within acceptable limits.

Samples of low, acceptable and high moistures are presented to the transmitter and it is scaled appropriately.  For example, low surface moisture is assigned a value of 0, acceptable 3 and high moisture 5.  The MCT460 features a 5.7” Operator Interface Display, 4-20 mA proportional analog output and optional Ethernet connection.  

 

Glue Pillow TREND PLOT Hot Melt PSA Application 051414

Guardian Cross Direction Web Profile System for Converting Applications

 

 

Converting Hot Line Post

Converting Near IR Poster

 

Guardian Scanning Frame Parameters

The Guardian Scanning Frame System Parameters allows the operator to quickly view scanner and transmitter diagnostics.  Scanner diagnostics reveal automatic edge detection, current and average moisture or coat weight measurements and web position.

Scan Parameter Diagnostics

Easy to Understand Graphical and Numeric Diagnostics

Modeling Different Products for NIR Transmitters – Global Vs. Separate Product Calibration

Global vs. Local Modeling for Different Products with NIR Transmitters

Near IR transmitters can be calibrated with separate channels for each product or they can utilize a global calibration.  A Global calibration is easier to generate while separate calibrations for each product usually provides tighter standard errors.

Illustrated below are three different product results based on Global versus individual (local) product codes (calibrations) within a product family.  The application data is for the measurement of PSA coat weight in the range of 8 to 40 GSM (grams per square meter) on polyethylene (PE) film at 25, 35, and 55 mils thickness.  The chart and graphs below compare results of a local calibration for each coat weight measurement on film with various thickness versus the PSA measurement of all with a single global calibration and the impact it has on accuracy and standard error.

Film Thickness

MCT PSA Accuracy

Local Model (+/-) GSM

MCT PSA Accuracy Global Model (+/-) GSM

MCT PSA Standard Error Local Model (+/-) GSM

MCT PSA Standard Error Global Model (+/-) GSM

Correlation

Coefficient

25 mils 0.1 0.3 0.05 0.05 0.99
35 mils 0.1 0.6 0.1 0.2 0.99
55 mils 0.1 0.4 0.1 0.4 0.98
All 1.0 0.43 0.99

 

Accuracy:  How close measurement is to target.  E.g. how close a dart is to the bull’s eye.  Accuracy is calculated from the Standard Deviation of Calibration Residual Values (difference between Lab and Calibrated MCT Values).

Precision:  How close the subsequent dart is to initial dart for same conditions (reproducibility/repeatability).

Standard Error:  Standard deviation of sample distribution for sample population mean or standard error of mean.  Think standard deviation and variable depending on sample population.

Standard Deviation:  How much variation from the average value.  Low SD indicates data points close to mean and high SD indicates values spread out over large range of values.

Correlation Coefficient:  Linear relationship between two variables, in this case Lab vs. MCT PSA mils thickness measurement.  All Correlation Coefficients (CC) are 0.99 which is close to perfect at 1.0.  Non-linear relationships can also be handled with NIR software technology, though not necessary in these applications.  Low CC indicates a low performance expectation.

 

PSA coating on PE

Universal Calibration Across Product Changes

 

 

NIR Transmitters Calibration Approach Comparison

NIR Calibrations for Single Products Vs. Global Calibration