PrediktIR II Coat-Weight Thickness Measurement Gauge
On-line Near Infrared (NIR) Moisture and Coat-Weight Measurement Sensor for Converting Industry
Overview
Replacing the ConvertIR, the PrediktIR II Coat-Weight Thickness Measurement Gauge is an on-line coat-weight and moisture measurement gauge using near-infrared (NIR) non-contact technology. The gauge provides a dependable, stable, and accurate on-line measurement, which allows the converting processes to be tightly and consistently controlled.
The gauge is suitable for use in many types of converting processes such as coating thicknesses of adhesives, water-based pigmented or clay coatings, wax coatings, polymer coating on paper, vinyl, PVC coating on paper and moisture in paper and board. The PrediktIR II Coat-Weight Thickness Measurement Gauge has a wide range of connectivity options including most modern Ethernet bus systems, allowing easy integration into production networks for providing real-time data exchange and improving process control and efficiency. The gauge is suitable for measuring coat-weight thickness or moisture, for applications where both parameters need to be measured simultaneously, please use the Series 9 Converting Moisture Gauge.
| Power Hub (PH) | Gauge Control Interface (GCI) | Gauge |
Key Benefits of On-Line Measurement
- Enhance product quality and consistency
- Reduce waste
- Avoid over-drying
- Faster start-up and grade changes
- Increase process productivity
Applications
| Algorithm # | Product | Measurement | Range |
| 1 | Adhesive on Paper or Textiles (Dry End) | Coat-Weight | 5 to 200 gsm |
| 2 | Adhesive on Plastic Film (30-150 um), General (Dry End) | Coat-Weight | 5 to 50 gsm |
| 3 | Paper and Board ( 40-120gsm) | Moisture | 1 to 15 % |
| 4 | Paper and Board (100-400gsm) | Moisture | 1 to 15 % |
| 5 | Water-Based Coatings on Paper or Textiles (Wet End) | Coat-Weight | 5 to 50 gsm |
| 6 | Urea or Melamine Formaldehyde in Paper ( Water-Based Wet End) | Coat-Weight | 20 to 200 gsm |
| 7 | General Moisture (as % of Wet Weight) | Moisture | 1 to 50 % |
| 8 | Cellulose Pulp Sheet | Moisture | 2 to 20 % |
| 9 | Cellulose Pulp Sheet | Moisture | 40 to 60 % |
| 10 | Reclaimed Paper | Moisture | 2 to 12 % |
| 11 | Extruded PE or PP on Paper | Coat-Weight | 5 to 100 gsm |
| 12 | PVA Thickness | Thickness | 10 to 100 um |
| 13 | PVA Moisture | Moisture | 3 to 15 % |
| 14 | Hotmelt Adhesive on Paper or Textiles (Dry End) | Coat-Weight | 5 to 50 gsm |
| 15 | PVC or PVDC on Paper or Textiles (Dry End) | Coat-Weight | 10 to 250 gsm |
| 16 | Rubber Adhesive on Paper or Textiles | Coat-Weight | 5 to 30 gsm |
| 17 | Wax Coatings on Paper (Dry End) | Coat-Weight | 10 to 20 gsm |
| 18 | Water-Based Coatings on Polymer Films (>30 um) | Coat-Weight | 5 to 50 gsm |
Specifications
| Component/Parameter | Description |
| Moisture Measurement Range | 0-95% Depending on Application |
| Coat-Weight Measuring Range | 5-250 gsm |
| Measurement Beam Patch Sizes | 60 mm or 25 mm Diameter |
| Standoff Distance | 250 mm ±100 mm (for 60 mm Beam Patch) 200 mm ±50 mm (for 25 mm Beam Patch) |
| Operating Temperature Range | 0-50°C |
| Process I/O | 4-20 mA Standard, 8 Digital Inputs (Opto-Isolated), 8 Digital Outputs (FFT Driven) |
| Digital Connectivity (Optional) | Ethernet IP, ProfiNet, Modbus TCP, Profibus, DeviceNet all from GCI |
| Gauge Head Construction | Stainless Steel (304) with Optional Air Purge Window |
| Environment Protection | Gauges and GCI IP65/Nema 4 |
System Configuration
The PrediktIR II Coat-Weight Thickness Measurement Gauge is designed to accommodate a wide range of possible configurations. Examples of single and two gauge configurations are shown below. PrediktIR II Coat-Weight Thickness Measurement Gauges, in 304 stainless steel enclosures, are connected to a PrediktIR II GCI with a 10-inch colour touchscreen and PrediktIR II PH delivering 24V DC.
Single Gauge Configuration
Two Gauge Configuration
What Our Customers Say…
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It is imperative that the adhesive is applied accurately by the coating machine, and the NDC gauge supplied by LIMAB UK enables our customer to monitor the machine’s performance whilst running. TS Converting were pleased to be able to work with LIMAB UK. Tim Self – Managing Director |
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The Pre-print division has invested in a film weight gauge on one of its two presses. This is part of a wider project to ensure we are delivering the correct amount of coating. The NDC gauge delivers quality assurance both internally and externally to our customers. The ease of functionality of the system, sales processes and service provided make NDC one of the best in the industry and I fully recommend an NDC system to any new business who are looking to invest in a film weight monitoring system. Sam Covell – Operations Director, Smurfit Kappa Pre-Print CRP |
The PrediktIR II is also available for use in the bulk materials industry, for more information please visit PrediktIR II Bulk Materials Moisture Gauge.