DFM-ALPHA is the world’s first online paint thickness measurement system with integrated closed-loop control technology (CLCTM). It continuously monitors coating thickness in real time and automatically adjusts the coater to keep the product within specification. Using advanced AI-driven algorithms, DFM-ALPHA analyzes key process data such as line speed, roll speeds, and dry film thickness (DFT). It also estimates coating properties like viscosity, solids content, and roll leakage to optimize performance. Unlike traditional systems, DFM-ALPHA delivers precise, real-time control without requiring complex hardware modifications. It detects even minor deviations and corrects them immediately, ensuring stable and consistent coating quality 24/7. The result is improved efficiency, reduced waste, and a consistently high-quality paint finish with uniform appearance and smoothness.
DFM Operation
DFM-Alpha and DFM-Ultra are advanced, easy-to-use online systems for highly accurate coating thickness measurement. They are based on patented Direct Measurement Technology (DMT™), recognized as a scientifically reliable method for precise film thickness measurement. A key advantage of DMT™ is that it is calibration-free, regardless of paint type or substrate. At the start of each new coil, the INTENSE MEASURE function captures up to 40 precision measurements from the first 2 metres of coated product. After that, the system continues measuring at user-defined intervals, typically every 20–90 seconds.DFM systems integrate with the line PLC to automatically detect when production starts and stops. In AUTO mode, measurement begins and ends without operator input. Operation is simple—users only need to set the target thickness, and the system manages the rest.
Coil Report Features
Coil reports can be generated by going into the production database and selecting the required coil numbers.
• The reports includes the coil start and stop time, the length painted, and the line speed,
• A graph shows paint thickness including the upper and lower control limits, and
• The coil report requires coil numbers at the DFMTM computer for each coil during production.
Coil-coating paint systems are designed to perform well with end-product features such as bends, cut edges, laps, scratches, and fasteners.
DFM measurement of the product guarantees quality and assurance that the coatings will perform to specification and meet paint thickness standards.
- Measurement accuracy is better than +/- 0.2 micrometres.
- Measurements are independent of paint type, substrate type, colour or paint thickness – no calibration is needed to cover this broad product range.
- DFM accurately measures textured and wrinkle coatings and can characterize the peak to valley depth and spacing of these finishes.
- DFM measures coatings from 3µm to above 100µm.
- 2 units are typically installed on the top finish to measure both sides of the strip, while most prime installations only require a single centrally mounted unit.
- All units, with the exception of the fixed-in-place centrally mounted units, have active edge detection that will locate the edges of the strip to position the units correctly to accommodate for changes in strip widths.
- All units have Z height control and will retract to a safe distance to clear the strip splice.
- DFM-Alpha and DFM-Ultra are installed above a strip turn roll after the paint curing.
- DFM-Alpha and DFM-Ultra is designed with extremely low maintenance requirements. Typical life will be up to 20 years.