Coil Coating Inspection
DJH Designs · Film Thickness
Film Thickness
Measuring System
Developed for both production lines and QC laboratories, this system uses advanced computer-programmed motion control for repeatable, highly accurate measurements. Eliminates operator error with consistent results machine to machine, site to site. Reads primer and topcoat film simultaneously. Measures up to 12 Mil (300 µm) using optional bit. No calibration required for different substrate materials. DJH View Software with multi-point averaging ensures consistent results.
DJH Designs · Solvent Resistance
MEK Rub
Test Machine
Semi-automated machine developed to eliminate inconsistent rub test results between operators. Programmable stroke counter (1–99,999 strokes), constant-pressure dead weight rubbing block, and quick-change solvent pad system ensure repeatable results from lab to production line. Fully pneumatic — no electrics — with CE certification. Minimises operator contact and exposure to solvents. 70 double rubs/min at 550 kPa operational pressure.
DJH Designs · Volume Solids
PVS1™ Paint Volume
Solids Instrument
The only instrument in the world performing a true Volume Solids Test — ASTM and ISO methods are not true volume solids tests. Measures paint volume solid content using non-contact laser sensors to ±0.5% accuracy. Works with WFM1™ to predict dry film thickness before painting begins. Four-minute analysis cycle. Reduces off-colour defects by up to 50%. Historical database of all PVS results included. Weight: 15 kg.
DJH Designs · Adhesion Testing
Scrape & Intercoat
Adhesion Tester
Standardises and quantifies intercoat adhesion beyond traditional coin tests by measuring shear bond strength between coating layers — a failure mode undetected by standard flexibility or adhesion checks. Usable as an online production tester or as a paint/substrate/process development tool. Travel speed: 50 mm/sec. Test panel: approx. 203 × 152 mm. Dimensions: 820 × 440 × 670 mm. Weight: 45 kg.
DJH Designs · Inline Dry Film
DFM-Alpha™
with Closed Loop Control
The world’s first online paint thickness instrument with integrated Closed-Loop Control (CLC™) — automatically adjusts the roll coater at the first sign of drift, 24/7, without operator involvement. Uses patented Direct Measurement Technology (DMT™): a laser ablates a 170 µm-wide point; no calibration required regardless of paint type, colour, or substrate. Measures 3–100+ µm to ±0.2 µm accuracy. Active edge detection, Z height control, and automatic coil splice retract. Designed for up to 20 years service life.
DJH Designs · Online Wet Film
WFM1™ Online Wet Film
Thickness Measurement
Measures wet film thickness (WFT) on the coater roll and predicts dry film thickness (DFT) on the strip before painting commences — eliminating out-of-specification product from the first metre of every coil. Uses a patented intrinsically safe confocal sensor with fully automated wipers; no calibration required. Checks film builds as low as 1 µm. Works in tandem with PVS1™ volume solids data for accurate DFT prediction. Film thickness range: 1.5 µm and up.ed for up to 20 years service life.
DJH Designs · Offline Film Profile
Phaeton™ Offline Film
Thickness Profile
The fastest, most accurate lab-quality film thickness profile instrument available. Up to 1,000 measurements across a 1,000 mm sample in under 5 seconds — no calibration for any coating, color, or substrate type. Laser ablation with high-precision displacement sensor: 49,000 measurements/sec at 0.03 µm resolution. Instantly reveals coater faults: unbalanced coater, out-of-shape rolls, localised ridges. Measures 3.5–220 µm to ±0.2 µm. Optional Color Scan adds full-width color profiling.
DJH Designs · Strip Joining
Strip-Lok™
Sheet Metal Joiner
Powerful 64-bit imaging and measurement platform for DJH film thickness instruments. Version 10 introduces fully automated layer detection with up to 360 data points per layer — eliminating manual operator interpretation. Includes point-to-point, parallel line, 4-point and 8-point averaging, radial, and angle measurement tools. ODBC-compliant archival database with image capture, annotation, reporting, and email export. Supports aluminium, galvanized, and glass substrates.
Objectra -·Coating Drill
Destructive Thickness Gauge
Coating Drill
The Säberg Coating Drill is a patented instrument for accurate determination of individual coating layers: primer, intermediate coat and top coat — measured on site or in the laboratory, on substrates including steel, galvanized steel, wood, concrete and plastic. A small hole is drilled and a measuring microscope is used to read each layer individually. Its compact, straightforward design makes the Säberg Coating Drill ideal for quality control, inspection and failure analysis.
Why Coil Coating?
The Most Efficient Coating Process
in Modern Manufacturing
Coil coating — also called pre-painted metal — is the continuous application of organic paints and coatings onto steel or aluminum coils before they are cut, shaped, and fabricated into finished products. This highly automated, high-speed process sets the quality baseline for everything from roofing panels and façade cladding to domestic appliances, HVAC units, automotive components, and furniture. Because coating is applied before fabrication, consistency and precision in measurement are not optional — they are structural requirements.
Unmatched Production Speed
Coil lines run at 60–200 meters per minute. A single shift can coat hundreds of tones of metal. Inline measurement is the only way to catch problems before kilometers of coil are scrapped or reworked.
Consistent Appearance Across Batches
Architects and fabricators specify colour and gloss with tight tolerances. Panels manufactured months apart must match. Without continuous online color monitoring and lab verification, batch-to-batch variation goes undetected until assembly.
Corrosion & Durability Performance
Pre-painted steel used in roofing or façades must resist corrosion for 20–40 years. Film thickness, paint volume solids, and cure quality directly determine coating lifetime — all measurable before fabrication begins.
Waste Reduction & Material Efficiency
Paint is the single largest material cost per tone of coated coil. Measuring paint volume solids (PVS) and wet film thickness on the coater roll allows precise dilution control, reducing paint consumption and solvent emissions simultaneously.
Customer & Regulatory Compliance
Coil coaters supply OEMs, construction firms, and appliance manufacturers with strict incoming inspection criteria. Documented measurement data — DFT, MEK rub result, PVS, adhesion — supports quality certificates and reduces customer returns.
Color Consistency (ΔE)
Online ΔE monitoring detects color drift in real time, before out-of-tolerance panels leave the line. Color variation that is invisible to the eye can be flagged at ΔE < 0.5 — critical for architectural panels where color matching between coils must be guaranteed.
Where DJH Instruments Fit in the Coil Coating Process
Each stage of the coil coating line has a specific measurement requirement. DJH instruments cover every critical control point, from incoming paint QC through to final inspection.
Industry Standards
Key Standards in Coil Coating Measurement
DJH instruments are designed and calibrated to comply with the major international test standards applied in coil coating quality control, customer acceptance criteria, and technical specifications.
ASTM D5796
Standard Test Method for Measurement of Dry Film Thickness of Thin-Film Coil-Coated Systems by Cross Sectioning
ASTM D5402
Standard Practice for Assessing the Solvent Resistance of Organic Coatings Using Solvent Rubs
ASTM D2697
Standard Test Method for Volume Nonvolatile Matter in Clear or Pigmented Coatings
EN 13523
Coil coated metals — Test methods (comprehensive European standard series for coil coating QC)
Industries We Serve
Coil-coated materials are used across a broad range of industries, from buildings and vehicles to appliances and industrial equipment. Our measurement instruments help manufacturers verify coating thickness, colour, adhesion and paint performance while maintaining consistent, efficient production.
InnovLab Solutions — Authorized DJH Designs Distributor, France
Discuss Your Coil Coating Measurement Requirements
Whether you need inline process control, lab verification, or a complete measurement solution from wet film to final adhesion test — our technical team will identify the right DJH instrument configuration for your line.