Automation of the coating process with inline controlKoenig & Bauer Inline Coating Thickness Control: Constant Coating Layer Thickness at The Push of a Button

• New inline coating layer thickness control for precise coating application, less waste and optimised coating consumption
• Real-time measurement and automatic adjustment ensure stable processes and promote sustainability
• Available for new and existing MetalCoat 483 installations

Koenig & Bauer MetalPrint presents the new inline coating layer thickness control for the MetalCoat 483

Controlling the coating layer thickness is a decisive factor for the quality of coated sheets and plays a central role in the production of metal packaging. With the new inline coating layer thickness control, Koenig & Bauer MetalPrint guarantees precise coating application and optimises production quality. Automatic and continuous measurement and controlled adjustment of the coating layer thickness reduces waste and optimises coating consumption.

Challenges of conventional methods

Manual checks of the coating layer thickness are often associated with uncertainty. To be on the safe side, more coating is often applied than is actually required. This leads to increased material costs and inefficient consumption. In addition, quality defects may only be discovered late in random samples, which puts further strain on the production process.

The solution: inline coating layer thickness control

The new inline coating layer thickness control feature from Koenig & Bauer MetalPrint solves these challenges. By measuring and controlling the coating layer thickness in real time, the system ensures stable process quality and minimises both waste and coating consumption. In addition to saving production costs, automation relieves the burden on employees, who can then concentrate on other tasks.

Real-time measurement and precise control

The system for the MetalCoat 483 combines direct drives on the coating machine with high-precision SpecMetrix® measuring probes that are installed directly after the coating machine.

"In collaboration with Koenig & Bauer MetalPrint, we are offering the metal packaging industry an innovative solution for optimising the coating process: next-generation coating thickness and film weight control. Our patented SpecMetrix technology, integrated into the MetalCoat 483, delivers highly precise real-time data that enables seamless quality control and supports efficient process control," explained Vivian Bravo Beck, Project Lead of SpecMetrix, an Industrial Physics brand.

The probes continuously measure the coating layer thickness, while the control function of Koenig & Bauer MetalPrint transmits the data to the machine control system in real time and evaluates it. During setup, operators can adopt setpoints from predefined coating recipes for the control or adjust target values individually. During production, deviations from the setpoint are automatically detected and corrected: the coating gap is readjusted until the setpoint is reached again. The precise control enables coating consumption to be reduced by up to 10%. This not only saves money, but also significantly promotes the sustainability of the production process.

Successful field test

In a successful field test of the inline coating layer thickness control at Blechwarenfabrik Limburg GmbH, the effectiveness of the solution was proven under real conditions. Various coatings were tested. The results showed a clear improvement in process stability, and operating costs were significantly reduced. Operators praised the automatic control and the safety that automatic control brings.

“The inline coating thickness control system we have installed is a marvelous example of how economic goals and ecological objectives can be combined. Resources are conserved, quality and efficiency are increased, and money is saved. The project also shows how tradition and innovation come together through the cooperation between the oldest printing press manufacturer, Koenig & Bauer, and the oldest metal packaging manufacturer, Blechwarenfabrik Limburg,” emphasises Hugo Trappmann, CEO of Blechwarenfabrik Limburg, President of the German Metal Packaging Association and winner of the German Environmental Award.

Available for new and existing systems

The new inline coating layer thickness control from Koenig & Bauer MetalPrint is available for use with new MetalCoat 483 coating machines as well as for retrofitting existing installations. It offers companies an innovative way to increase production quality while saving costs and resources.

With this solution, Koenig & Bauer MetalPrint is setting new standards in coating technology and supporting companies on their way to more sustainable and efficient production.