Boosting productivity on the plant floor and making INDUSTRY 4.0 feasible in the paint and coatings business.
COLORCELL was conceived with the objective of quickly and accurately measuring and adjusting one of the most complex properties of the paint industry, which is Color. We offer a Laboratory version and another for Industrial On-Line use, available to enable the process manufacturing automation, reducing the production cycle time and improving product quality.
Process automation, with effective results and almost thirty years of operational history. (Only now available for marketing separately)
Variability index (Sigma level) using COLORCELL for Online control and adjustment, six times better than the conventional technique.
The “wet” color measurement technique, due to its high accuracy, allows the reduction of saturation (coverage), with consequences in reducing the pigmentation package costs.
Reduces the color approval lead time by at least 60%, allowing the reduction of the cycle time, increasing the production volume and reducing stock.
In the industrial version (Process Version), it uses Artificial Intelligence resources (Machine Learning) to optimize formulas, using learning to continuously incorporate predictive corrections related to the variability of raw materials present in formulas.
It uses DATACOLOR spectrophotometer and Color Correction software, facilitating the maintenance and development of Colorimetric Databases using DATACOLOR’s worldwide technical assistance network.
Below we present a representation of the measurement cycle of the color variable, by the Conventional Technique, which shows the slowness associated with this technique, to obtain the measurement result, and its several stages that lead to greater uncertainty in R&R, due to the sum of the variability of the various stages until the results are available.
COLORCELL performs COLOR measurement using a wet spectrophotometric technique (in liquid form).
The measurement is performed through a continuous flow cell that keeps the material completely homogeneous during the measurement, unlike static cells (cuvettes) that do not have reproducibility for paints.
COLORCELL has an international evolutionary patent filed in 2019, however it has been used in industrial plants since 1992, both in Brazil and elsewhere in the world.
COLORCELL was originally born to enable the implantation of plants with continuous paint production technology with a high level of automation, and operating autonomously without contact with operators.
Continuous plants for Original Automotive and Refinish manufacturing paints, have been operating with this technology in Brazil and abroad for about 25 year.
The WET COLOR measurement technique, in addition to reading speed and enhancing quick and precise adjustments, has excellent sensitivity and a repeatability and reproducibility superior to the conventional technique.
Attempts have been made in the past to use “static cuvettes” to measure COLOR in paints in liquid (wet) form, however due to the effects of sedimentation, fluctuation and “seeding” of pigments, it has not been successful, observing there is a great variability of the measurement, which made the use of static systems impossible.
COLORCELL, having in mind that it was conceived for color measurement in continuous processes, was born with the DYNAMIC measurement philosophy (in flow) which avoids the appearance of the effects previously mentioned and keeping the material in its homogeneous form throughout the cycle measuring.
COLORCELL, associated with a Mass Flow Transmitter by “Coriolis” effect, also delivers, in addition to COLOR, other material characteristics, such as VISCOSITY and DENSITY, becoming a powerful weapon in the automatic control of manufacturing processes of paints and coatings, enhancing the implementation of the long-awaited Industry 4.0 in the paint segment.
Other analyzers can also be incorporated into COLORCELL, further increasing its analytical capacity for process controls, such as PH, Conductivity, “TRANSMICELL®” (measurement of Strength, Color Position and Hiding Power), etc.
Hardware resources specially created for the equipment, combined with control software with artificial intelligence resources, make the equipment extremely flexible and easy to operate, intensifying its gains.
The purpose of this equipment is, in essence:
Other analyzers can be added to COLORCELL, further increasing its coverage.
COLORCELL’s analytical capacity can be amplified by incorporating it for example:
Hardware and software resources specially created for the equipment, combined with DATACOLOR’s Colorimetry Software, integrated with artificial intelligence algorithms (Machine Learning), enhance the equipment’s functionalities.
IMAGES AND DESCRIPTIONS.
Below we present the curves of the Reflection Spectrum (Figure 1 and Figure 3), showing the profiles obtained for “dry” and also “wet” measurements obtained from COLORCELL, for a series of tests with solvent-based enamel paints, for the colors: blue, green, yellow, red, light gray, medium gray and dark gray.
Through (Figures 2 and Figure 4) we also present the correlation curves obtained for the values “dry” versus “wet”, for each paint tested, with their respective “correlation coefficients” (R²), case by case.
The data presented above, demonstrate total coherence between “dry” and “wet” measurements, presenting only a proportional deviation in all wavelengths and for all tested inks, and it relates exclusively to the measurement method.
This is even more evident when we analyze the Correlation Curves (Figure 2 and Figure 4), where in all cases, the R² (correlation coefficient), has average values in the order of 0.99.
Although the coherence between colorimetric measurements is excellent (dry x wet measurement methods), for a satisfactory migration to the use of the “wet basis” measurement and adjustment technique, the entire construction of colorimetric databases (Databases) of “Colorant Blends”, as well as the memorization of color patterns, must be carried out in its liquid “wet” form).