Chromate Conversion Coatings CCCs on Metal

CCCs are frequently applied to steel coil and aluminium coil surfaces to render them corrosive resistant and to establish an adhesive base for organic coatings.  Chromium VI, hexavalent chromium has been the most predominantly used form, but it’s usage is being curtailed through RoSH legislation owing to it’s toxicity. Chromium III is safe to use, and is still being used by many aluminium manufacturers in addition to newer alternatives based upon phosphates, manganates, silanes, etc

As NIR measurement is non contact and non destructive, the  MCT 360 can be simply installed on line after the coating has been applied to measure the coat weight on a continuous basis, enabling automatic or manual adjustment to the coater. Control of coat weight is important as it impacts the physical and chemical properties of the sheet metal.  The CCCs also “tie” the paint to the metal substrate to reduce or eliminate paint peel issues.  This measurement is similar to other converting applications.

The gauge is installed parallel to and at a distance of 150 – 300mm from the metal sheet as it passes over a large diameter steel roller, or approaches rollers (for minimal web flutter).  Measurement is made on the wet coat weight but the read-out is in terms of dry coat weight.  The solids ratio must be kept constant or be known, so that a correction factor can be applied to the measurement read-out.


Dry coatweight range Expected measurement accuracy
*3-8 mg m-2  +/- 0.05 mg m-2 


* Note other coat weight ranges can be measured.


CCC Measurement on Metal




CCC Coating on Metal

AIMCAL Conference Charleston SC features PSC Paper Presentation


Aimcal logo

Aimcal logo

Process Sensors Corp. (PSC) will be an active participant and sponsor at the AIMCAL  Web Coating & Handling Conference 2013 Charleston, SC.  PSC will participate in Sunday and Monday Table Top Events and PowerPoint summaries.  PSC will also present a paper on Monday, October 28th in Aimcal’s Processing Technology section at 10:30.  The paper discusses “Controlling Re-Moisturizers to Reduce Edge Curl and Improve Web Flatness with Cross Direction Web Moisture Profile”.

AIMCAL Conference is October 27 – 30th in Charleston, SC.  Industry experts gather to discuss problems and solutions.  We hope to see you there!




Scanning frame

Guardian Web Profile System with MCT Series of Transmitters

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Bellagio Fountain Show Las Vegas

Process Sensors Corp. (PSC) specializes in NIR transmitters for the measurement of moisture, coat weight, and film thickness in the packaging industry and moisture, oil, flavorings and degree of bake in the food industry. The MCT NIR transmitters are also used in mining, powder, and chemical industries.  Pack Expo offered an opportunity to exhibit our products!

The MCT360 NIR Transmitter is routinely used at the inlet and exit of dryers, re-moisturizers, flavoring drums and other unit operations.  The Guardian Cross Direction Web Profile System incorporates the MCT360 with an automatic scanning frame and encoder to supply a zoned web profile for monitoring or control of paper, film, foil or metal webs.  The MCT330 is a stainless steel NIR gauge for high temperature, wash down or hazardous environments.  The MCT660 Bench Top Analyzer is designed for at-line or laboratory measurement to speed grab sample analysis.  Process Sensors also introduced the top of the line MCT460 series of NIR transmitters.

PSC also manufactures the RFM1000 for process moisture measurement in thicker packaging materials and whole nuts and beans and the RFM1000 BT for at-line and lab Radio Frequency measurements.  PSC IR Division markets a wide variety of Thermal Imaging and Temperature measurement systems for process and hand held applications.

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Pack Expo Booth Set-Up



Hot Melt Thickness Measurement On Film

Hot melt data

Lab vs. MCT Transmitter

Hot Melt measurements on film 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 recipes for web width, scan speed, zone average, and data logging digital outputs. This is a complete system to provide the highest value performance to cost ratio. The system can supply CD Web Profiles and MD Trends for hot melt thickness, moisture and temperature. Multiple measurements can be displayed on a single screen.  The MCT Series of NIR transmitters can also measure hot melt thickness on film in a fixed position.

Hot melt grab

Hot Melt Lab vs. MCT

Columnated Beam Assembly for Narrow Web and Web Edge Measurement

Columnated Beam Assemblies for Narrow Webs and Web Edge measurements are becoming an increasingly important tool for packaging material suppliers in the food, pharmaceutical and other industries.  Typically these applications require a much smaller spot size to avoid the irregularity on the body of the web which may contain intentional voids or reception spots for capsules, pills, vitamins etc.  In these cases there is usually a continuous band of hot melt coating on the narrow web edge for both lab and process measurements.

There are two common methods to narrow spot size.  Masking the light beam essentially blocks light energy into a smaller profile using less light and decreasing the signal to noise ratio.  Optical lens size reduction maintains energy and a strong signal to noise ratio.  Sometimes a combination of the two techniques are employed to best optimize spot size and shape for narrow webs.  Please contact Process Sensors to discuss your application at 508.473-9901.

Narrow Web comparison of optical to mask technique

Narrow Web Columnated Lens Assembly

Nonwoven Moisture Measurement with Process Near IR Transmitter

nonwoven color fabric

Polypropylene Nonwoven

Nonwovens are usually manufactured from fibers or filaments as sheets or webs bonded together thermally, mechanically or chemically.  The term nonwoven indicates that they are not made by weaving or knitting. Sometimes a certain percentage of recycled fabrics and oil-based materials are used in nonwoven fabrics for strength characteristics for a given application. Nonwovens are generally recyclable and have gained favor in single use and disposable markets for ecological or “green” reasons and increasingly function as a substitute for polyurethane foam.  They are also used in the manufacture of bullet proof vests, very flexible material for a large number of applications.

These nonwoven engineered fabrics can have the same appearance and strength as woven fabrics.  Nonwovens can be thermally bound by adding a resin and heating up the web to melt the resin into the fibers or chemically bound with an adhesive or mechanically bound such as felts.  PET (polyethylene) and PP (polypropylene) are common chemical formulations used in the manufacture of nonwovens.

Near Infrared (NIR) process transmitters have several applications in the nonwoven manufacturing process that can reduce costs, increase line speed and quality control.  Primary application is moisture measurement at the dryer exit but these NIR transmitters can also measure water based binder coatings, and for low weight nonwoven webs, basis weight based on the hydrocarbon absorption peak at 2.34 µ.  Process Sensors MCT series of NIR transmitters meet these application requirements.  Please contact us at 508.473-9901 to discuss your application.