Tips for Choosing Colour Coating Line Manufacturers

Did you know that 30% of colour coating defects on metal strips are caused by equipment inaccuracies and process mistakes? Finding a manufacturer that can provide a colour coating line that meets international standards is critical. Choosing a colour coating line manufacturer is a big decision that can cost from $15-$60 million, depending on the type of line.

A single color coating line can last 20-30 years. The configuration of a colour coating line defines its product quality, cost per ton, and delivery speed. This article requires basic knowledge of the colour coating lines from the reader. It will focus on the key aspects to consider in selecting colour coating lines. We will provide 7 key research-backed selection criteria that the world's most successful coil coaters use.

Define Your Exact Process Configuration

The first step is to find the right process you need for the desired output. Remember that it's an irreversible process or requires major overhauling if any change is required. Any modification later can cost millions. For a long-term business, make the decision smartly, as a color coating line manufacturer can provide you with a 2-coat line. However, if you require a 3-coat line in the future, it will have a major financial impact. Define your requirements, like the oven length, coater arrangement, and strip storage capacity, to meet business demand.

1.1 Select the Right Coating System for Your Market

There are three major coating systems that offer different qualities and longevity:

• 2-Coat/2-Bake: It is the most common configuration for a colour coating line. Around 70-80% of global meta strips are made using this process. The process has one prime coat and one finish coat, followed by individual baking ovens. The configuration allows 10-20 years of durability in the finished product.

• 2-Coat/2-Bake + Pattern Printing: For production facilities that require decorative metal strips, an additional pattern-printing unit (gravure or inkjet) can be added to the production line. Adding patterns of wood or stone structure adds value to the sheets, making them ideal for decorative applications.

• 3-Coat/3-Bake: The overall setup configuration remains the same. However, an additional clear coat or top lacquer is added as the final step. It increases the durability of the sheets to a 30-40 year warranty. Evaluate your target audience and product before making the selection.

1.2 Consider Value-Added Modules

While the core configuration is necessary for producing standard strips. Value-added features can expand your production range. Here are some features to consider:

• Protective film lamination

• Back-coat station

• Tension leveller for exposed panels

• Hot/cold laminating for PCM/VCM

• Embossing or printing units

Extensive Industry Experience

The colour coating line manufacturer should have extensive experience in the field. A new or recent supplier may not have a mature network or massive feedback database for process improvement. Colour coating lines are a set of complex machines that operate at high speeds. Everything from their design, preventive maintenance guides, and vendor support matters. Evaluate if the manufacturer checks the following:

• Number of Installations: Look for a generous amount of installations, 50+ at least, in which the selected line installations hold a significant number.

• Experience with High-Speed Lines: Look for their experience with 150-220 meter/min production colour coating line that works on 0.11–1.2 mm GI/GL/Aluminium.

• Success in Turnkey Projects: Successful project deliveries outside their home country.

• Track Real Customers: Contact their real customers for feedback.

Insist on Latest-Generation Coater Technology

While the technology in coating is evolving, there are proven technologies that offer the best outcomes. They are sure to remain relevant for years to come. As a production facility, consider the following latest-generation technologies:

• Servo-Driven S-Wrap & U-Wrap: These finish coaters with a quick-colour-change feature can change color using precise control in less than 5 minutes.

• Independent 3-Roll Reverse-Roll Stations: The paint is the biggest asset, and overpainting can turn into a massive cost over a period of a year. Therefore, using a 3-roll reverse-roll station can ensure ±1 μm thickness control.

• Eccentric Offset Rolls: Thin-gauge (0.11–0.18 mm), particularly aluminum, can scratch. The eccentric offset rolls protect the surface of the strip.

• Automated Viscosity & Temperature Control: Controlling these parameters results in proven rejects below 1.5%.

Focus on Oven Performance and Energy Recovery

The oven is the part where the polymerization takes place. Ensuring that the oven can control the temperature within a very short window can result in high-quality output free from defects. Uneven heating can lead to blistering or poor adhesion. Moreover, consider modern technologies that recycle heat around 78% cutting down on energy costs. The oven should be able to handle paints with low VOCs. Here are the key points to consider for ovens:

• ±2 °C Temperature Control Window

• Thermal Oxidizer + Energy Recapture

• Low Gas Consumption ≤0.35 CBM/ton

• Handle Environment-Friendly Paint

Insist on Short Project Timelines

Order registration, shipment, installation, commissioning, and testing are a long process. In case the project is not in the homeland. Consider short timelines for project delivery. Every day that you are unable to operate contributes to the indirect cost of the project. Premium colour coating line manufacturers like HiTo Engineering, and other top-tier CCL manufacturers can deliver turnkey projects in 9-12 months. This is exceptional in comparison to the 18-24-month average. Look for the following indicators from the CCL manufacturer under focus:

• Modular Construction

• Parallel Engineering

• In-house Fabrication

Genuine Lifetime Support Package

A good colour coating line manufacturer provides genuine support. They follow a holistic approach owing to their experience in the field. A manufacturer should mention the following services for their production facilities:

• Minimum 4-week operator & maintenance training

• 24/7 remote diagnostics + guaranteed spare parts for 15 years

• Paint supply partnership & colour-matching laboratory support

• Free process optimization visits in the first two years

• 98%+ first-year uptime guarantee with penalty clause

Conclusion

Following these 7-criterias will lead you to selecting the ideal colour coating line manufacturer. Your facility will have a future-proof configuration and a supplier that provides you with the ideal support. Their extensive experience will ensure the swift resolution of problems and the best training for the operators to tackle common problems. 

By selecting the right configuration, evaluating the manufacturer's experience, analyzing their technology, and capability to deliver timely, can result in a quality product with excellent ROI. A well-evaluated CCL manufacturer can result in a 3.5–4.5 year payback. If you are looking for a company that meets all the standard criteria of a colour coating line manufacturer with more than 80 installed lines worldwide is HiTo Engineering. They leverage massive Chinese manufacturing experience and technological advancement to produce premium lines. Visit the HiTo engineering website to learn more or contact their sales team member.