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COLOR COATING LINE DEFECT MANUAL

Defect Explanation Reason Remidy

Applicator Roll Blisters Repeatative spots of no paint Air bubble on applicator roll rubber coating or foreign particle Measure distance between marks, check applicator roll
on applicator roll surface for defects, if found, replace applicator roll

Cut or groove in applicator roll, caused by sharp/broken edge Measure distance between marks, check applicator roll
Applicator Roll Marks Continuous line or repeatative mark of thick paint or burr surface for defects, if found, replace applicator roll

Flat spot on applicator roll, air bubble in rubber of applicator Measure distance between marks, check applicator roll
Applicator Roll Bruice Marks Continuous faint line or repeatative faint spots roll, rubber coming loose from applicator roll, variation in surface for defects, if found, replace applicator roll
hardness or thickness of applicator roll rubber.

1. Retract the applicator roll head and remove the dirt


Dirt Streaks Unpainted line or spots, under which primer is visible Dirt or piece of rubber caught between applicator roll and strip part
2. Guide the dirt particle with some stick out of the
applicator roll

Pick Up Roll Marks Repeatative Spots of very thin film and/or no paint Dirt or rubber stuck on pick up roll Clean pcik up roll, if problem does not resolve, change roll

Ghosting Patchy, non uniform paint surface Improper speed of pcik up roll, causing less quantity of paint Adjust roll speed ratio
supplied to applicator roll

Incorrect speed of pick up roll, incorrect height of paint tray or


Paint Starve Thin and/or patchy paint film paint supply pump malunction, causing less paint quantity Adjust roll speed ratio, use appropriate paint tray height
supplied to applicator roll and check paint supply pump

Applicator Roll Chatter Line marks across strip width Incorrect applicator roll speed causing vibration, uneven Adjust roll speed ratio and gap between strip and
contact between strip and applicator roll applicator roll

Fine craters on wet film which leaves rough dry film (like Adjust roll speed ratio and gap between strip and
Frosting sand paper) Too mcuh wet film applied on strip applicator roll

Heavy paint on the edges due to grooves on AR and/or bad Check wet film thickness. Adjust gap between strip and
Edge Beading Blisters on paint film on the edges of strip strip profile (flatness) applicator roll. Check steering system for movement and
adjust according to the strip profile

Flow Lines Too many small lines along the length of coil Incorrect applicator roll speed for the paint rehology (viscosity) Adjust roll speed ratio. Check/adjust paint viscosity

Gloss Streaks Difference in gloss on strip surface Poor paint movement in paint tray, poor agitation in drum Stir paint tray, proper agitation in paint drum
before feeding to tray

Pigment Streaks Small pimples of paint on strip surface Paint pigment combines with each other and make a lump and Stir paint tray, proper agitation in paint drum.
settle down in bottom. Check/adjust paint viscosity
Low hardness of paint due to inaccurate tension and/or low Adjust line tension and pressure between back up roll and
Pressure Blisters Small craters across strip pressure between back up roll and applicator roll applicator roll

Dirt Spots Spots on top of paint or with in paint Dust could drop from oven on strip surface Clean prime and finish oven environment

Cleaner substrate input and quench water, increase


Fish Eyes Creater type marks with primer visible under it De-wetting due to oil/grease on the strip surface, quinch water pressure of squeeze rolls, proper rubber hardness of
not clean, water on strip surface
squeeze rolls

Retract coating head near stich between two coils and use
Uncoated Sections Uncoated sections on strip Coating head retracted in running line dummy coil in between

Low dry film thickness, incorrect curing, wrong color quantity Adjust wet film thickness to obtain correct dry film
Poor Color Color difference between standard and painted strip supply to strip thickness, set oven temperature and line speed
coherently, adjust roll speeds and pressure

Incorrect curing (under or over bake), pretreatment, substrate Check paint and pre treatment chemicals, peak metal
Poor Paint Adhesion Removal of paint/primer from strip during testing contamination temperature, strip contamination

Rolls impressions on substrate appeared during skin passing Prevention at skin pasing/rolling stage by changing skin
Substrate Marks Faint marks appearing on the strip from under the paint and/or rolling pass/rolling mill rolls

Grading Crieteria High Defect intensity: Secondary


Low Defect intensity: Prime, if defect is on less than 10% of coil length, else Second