In-line measurement and correction of Color and physical properties

Symposium on Color and Appearance Instrumentation April 15-16, 2003Chicago, IL

Girish Malhotra, President, EPCOT International, Pepper Pike, OH, USA Carlos Arthur Peixoto, Process Engineer, Eduardo Schotgues, Software Engineer, Paulo R. Pfeil Instrument Engineer- NTP Production Technology Center, Renner Herrmann SA, Porto Alegre, Brazil

CHARACTERISTICS MEASURED

• COLOR

• PHYSICAL PROPERTIES

• DISPERSION PARTICLE SIZE

IF SPECS CAN BE CORRECTED AND MET WITHOUT SAMPLING

BENEFITS WILL BE:

• REDUCED PROCESS CYCLE TIME

• IMPROVED PROFITABILITY

• HIGHER AND CONSISTENT QUALITY

TECHNOLOGIES

• COLORCELL (REFLECTION ONLY)

• MULTICELL (TRANSMITION AND REFLECTION)

Fixed Plate

Fixed Plate

WIPER

Spectrophotometer

Reflection

Liquid

COLORCELL TECHNOLOGY SCHEMATIC

Figure 1

Fixed Plate

Movable Plate

WIPER

Spectrophotometer

Reflection

Transmission

White Light

Liquid

Transmission

MULTICELL TECHNOLOGY SCHEMATIC

Figure 2

Electronic finger print is created and matched.

Figure 3

MULTICELL

TECHNOLOGY APPLICABILITY

• COATINGS (ARCHITECTURAL, AUTOMOTIVE, WOOD, INDUSTRIAL, PAPER)

• PRINTING INKS

• PIGMENT AND DYE DISPERSIONS

• TEXTILES

• COLORANTS

• COSMETICS

• FOOD

• MINERALS

MULTICELL TECHNOLOGY

• WHITE LIGHT vs. WHITE BASE

• REFLECTION AND TRANSMISSION THROUGH FILM MEASURED CONTINUOUSLY

• ELIMINATES USE OF WET STANDARDS

• CONTINUOUS COLOR, STRENGTH AND HIDING POWER MEASUREMENT

• CONTINUOUS VISCOSITY, DENSITY AND TEMPERATURE

• FEED RATES ADJUSTED IN LINE TO PRODUCE QUALITY

TECHNOLOGY (cont.)

• DEVELOPED BY RENNER HERRMANN, S. A.

• COMMERCIAL

Du Pont Performance CoatingsAutomotive refinish coatings (Brazil)

E. I. du Pont - Mt ClemensAutomotive primers (Michigan)

Renner Sayerlack (Brazil)

CADAM ( Caulin do Amazonas )

• Other installations underway

FINANCIAL IMPACT

• INVENTORY INTEREST

• OBSOLESCENCE

• MANUFACTURING COST

• REDUCED WASTE

• SERVICE AND QUALITY

FINANCIAL IMPACT

Savings 15-25%

Figure 4

Final Product

MIXER

Recycle Tank

MULTICELL

MANUFACTURING CONFIGURATION

Liquid 1Liquid 2

Liquid 6

Liquid 5

Liquid 3

Liquid 4

Liquid 7

Liquid 8

Tank

TEST RESULTS

Table 1

Kaolin Samples Al2O3 SiO2 Fe2O3 TiO2

% % % %Theoreticalcomposition

39,8 46,3 0 0

A1 37,7 46,6 1 0,1A2 37,7 46,5 0,9 0,1B 39,1 46 0,6 0,7C1 35,5 47,5 1,9 1,5C2 38 44,6 1,9 1,2C3 38,1 44,5 1,9 1,2

KAOLIN

Figure 5

40

52

64

76

88

100

400 450 500 550 600 650 700

Wavelength (nm)

R(%)

A1 A2 B C1 C2 C3

CONVENTIONAL DRY METHOD

Figure 6

0

15

30

45

60

75

400 450 500 550 600 650 700

Wavelength (nm)

R(%)

A1 A2 B C1 C2 C3

WET METHOD USING COLORCELL

Colorcell wet and dry sample

020406080

100

400 500 600 700

Wave length

% R

efl

ec

tio

n

wet sample

dry sample

Wet DE =0.24

Dry DE =0.22

Yellow solvent coating Figure 7

Wet DE =0.27

Dry DE =0.28

Blue solvent coating

Colorcell wet and dry sample

010

2030

40

400 500 600 700

Wave length

% R

efl

ec

tio

n

wet sample

dry sample

Figure 8

Figure 9

Reflection Dry Curves

0

10

20

30

40

50

60

70

80

90

100

400 450 500 550 600 650 700

NM

%R

STANDARD

BATCH

WOOD COATING DYE

Figure 10

Multicell Transmission (20µm)

0

10

20

30

40

50

60

70

80

90

100

400 450 500 550 600 650 700

NM

%T

Standard

Batch

WOOD COATING DYE

Conventional Method

0

10

20

30

40

50

60

70

80

90

100

400 450 500 550 600 650 700

NM

%T Standard

Batch

Figure 11

WOOD COATING DYE

Figure 12

Relation between Kstd and Kb

0.00

0.50

1.00

1.50

2.00

2.50

400 450 500 550 600 650 700

NM

Kstd/Kb(Multicell)

Kstd/Kb (Conventional)

WOOD COATING DYE

31.35 1.65

3.44 0.31

123.37% 99.40%

Formula

D transmission

D reflection

Strength

Colorants

Uncorrected

First Correction

Component 1 0 2.150

Component 2 0 1.130

Extender 1 0 17.717

Component 3 100 79.004

Table 2

COLORANT EXPERIMENT ITERATION USING MULTICELL

Figure 13

COLOR EXPERIMENT DATA

0.00

20.00

40.00

60.00

80.00

100.00

120.00

400 450 500 550 600 650 700

nm

%T

Approved

Uncorrected First Correction

SUMMARY

• TECHNOLOGY IS COMMERCIAL.

• PRODUCTS DEVELOPED IN ANY PART OF THE GLOBE CAN BE PRODUCED AT THE MOST COST EFFECTIVE PLACE.

• TECHNOLOGY CAN BE RETROFITTED IN EXISTING PLANTS.

• MARKET AND PRODUCT DEVELOPMENT TIME IS SIGNIFICANTLY REDUCED.

THANK YOU VERY MUCH.

• QUESTIONS

CONTACT:

Girish Malhotra, P.E.EPCOT International29150 Bryce RoadPepper Pike, OH 44124epcotint@ix.netcom.com216-292-0626(P)216-591-0932(F)http://www.epcotint.com

Profitability through Simplicity