Automatic Closed Loop Color Control

                                                                       This Product is currently only available in North America.

Automatic Closed-Loop Color Control (ACLCC) System

For Extruded Plastics Manufacturing

Optimize operator efficiency while ensuring consistent color quality throughout a production run with this PLC-based Closed-Loop Color Control system.  The system was developed through a strategic partnership between X-Rite, Inc., the industry-leading manufacturer of color measurement solutions, and Plastore, Inc., a leading manufacturer of volumetric and gravimetric feeders for the plastic manufacturing industry.

The system uses colorimetric data from the VeriColor Spectro in-line color spectrophotometer to control the feeder rate, automatically adjusting material flow to maintain preset color tolerances. It also adjusts for bulk density variations of color concentrates and color variations caused by embossing patterns and can be run in concert with gravimetric systems that control virgin, regrind and other additives.

The system ensures consistent color quality throughout a production run, freeing operators to focus on additional value-added activities while minimizing scrap and product recalls. 

Challenges in Plastic Extrusion Manufacturing

Plastics production demands tight tolerances and efficient use of materials. This places a heavy burden on operators and equipment, particularly when it comes to producing color components that must meet exacting standards. 

Maintaining a high level of color quality control is a challenge that can often lead to material waste, line shutdown, extensive operator involvement, and product scrap and rework. Often times, variation between operators can impart error in the process leading to unnecessary changes in the production run. Insuring timely QC checks can be challenging and when missed, can result in out of spec color, increased scrap cost, or worse, sending out of spec product to the customer.

The Solution – Automatic Closed-Loop Color Control

X-Rite, Inc. and Plastore, Inc. have developed the solution that optimizes operator efficiency while ensuring consistent color quality throughout a production run: Automatic Closed-Loop Color Control (ACLCC).  This system takes over much of the hand      eye work associated with production, providing an automated closed-loop color control system that minimizes the need for operator involvement while improving quality control and reducing material waste.

The system consists of VeriColor Spectro, a high resolution, lab-grade color spectrophotometer manufactured by X-Rite Inc. designed for in-line color monitoring, and a PLC with closed-loop color control software developed by Plastore, Inc. The solution uses colorimetric data from VeriColor Spectro to control the feeder rate, adjusting material flow automatically to maintain color within preset color tolerances. The PLC allows programming downstream actions such as short cutting boards or sorting when the system indicates color is out of spec.

              The system minimizes the need for operator involvement while improving quality control and reducing material waste.

System Features:

VeriColor Spectro:

• 31 point, dual beam non-contact spectrophotometer.
• LED illumination providing >20 million flashes.
• Ambient light rejection, no additional shrouding is necessary.
• 1” measurement area.
• 4” measurement distance.
• White Repeatability:     ≤ 0.035 Max ∆E
• Reproducibility:              ≤ 0.20 Avg. ∆E
• Calibration:                 White calibration required once every 30 days.
• Operating Temp:        0 – 50° C (32 – 122° F) C without environmental enclosure.                                 
                                         PN# VS410-801 (up to 75° C with environmental enclosure)
• NEMA 4 / IP67 rated for industrial environments.
• Patented technology (US patents 7,773,221 - 6,888,633 - 7,262,853 - 7,145,657)
  

Closed-Loop Color Control System:

• Touch screen PLC with color-control software allows easy operator set-up and control.
• Closed-loop color control of color feeder speed based on
  L*, a* or b* process variables,
• The system automatically adjusts for bulk density variations of color
  concentrates, feed screw wear and other variations.
• Can be run in concert with gravimetric systems that control virgin, regrind 
  and other additives.
• Color Specification and tolerances may be set for all variables and may be
  non-symmetric (example: L* tolerance may be +0.6 ∆   and – 0.3 ∆)
• Ability to synchronize a line with QC lab via Delta values.
• “Boost” speed designed to speed up color changes and reduce scrap by increasing material rate while searching
   for “stable”  color. Stable color is defined by seeing a predetermined number of samples all falling within a set deviation of       each other. 
• Calibration reminders automatically displayed based on number of scans and time since last calibration
• Automatic logging of Out of Spec and Out of Tolerance conditions with detailed information about the process condition
• Screens provide detail on the number of times an alarm has occurred, as well as overall alarm list
• Historic data logging is done automatically and stored to a compact flash drive for retrieval via USB or remotely on a network by FTP.
• All process variables are charted in real-time and can store 100 scans of data for viewing on screen
• Standards (recipes) may be stored to the system and retrieved using browse and search functions
• Standards may be modified anytime, as well as re-saved at the end of a run to maintain the latest set of parameters
• Feeder may be set into Manual Mode at any time and “locked” into this mode by password 
• All critical areas are password protected.
• Supports full diagnostics of VeriColor Spectro.
• Operators have the option to sync a online production standard with the QC lab color standard via lab Delta values.
• Alarms for out of spec and out of tolerance conditions are logged automatically and include critical process condition data.
• Process variables are presented in real time. 

System Advantages:

Automation provides monitoring and control of color variation, adjustment for certain variables that affect color quality, enabling downstream containment of defective product and capturing historical and accurate data for Statistical Process Control.

Cost Reduction results from improved color changeover efficiency enabled by a programmable Boost Mode, automatic detection and correction for color drift, and downstream containment of defective product.

Learning is simplified by end-user constructed workflows and intuitive user interfaces, minimizes training and improves operator effectiveness.

Containment insures reduction in scrap cost and risk of non-conforming product reaching the customer.

Compatibility with existing infrastructure using industry standard software protocols and architectures.

Automatic Closed Loop Color Control