To maximize coating line speed safely, increase speed in small steps of about 3% per batch and check sheet skew data after every run. The IS416 Sheet Skew Measurement System records the average and standard deviation of sheet skew at the coater exit, so you can see whether sheet control still holds at the higher speed before you go faster.
Using this method, many canmakers have raised line speed by about 7%, producing about 800,000 extra sheets without major issues.
Key takeaways on coating line speed
- Raising line speed is one of the most reliable ways to increase productivity and profit, but faster sheets are more likely to skew at the coater.
- The IS416 records skew statistics, including the average and standard deviation, for every batch, giving you the data to decide whether the line can go faster.
- Increase speed by about 3% per batch until a problem appears, then step back slightly.
- Canmakers using this process have increased line speed by about 7%. In Innosen’s example computation, a 3% increase on a 5,000 sheets/hour lacquering line adds about USD 109,200 in extra profit.
Why increase coating line speed?
Line speed sets how many sheets your coating line produces per hour. Running faster is one of the most reliable ways to raise manufacturing productivity and profitability, because the same line, crew and shift produce more sheets.
The risk is alignment. As speed goes up, sheets are more likely to skew (rotate) at the coater, which places lacquer on the weld margins and causes weld wire breakage, spoilage and downtime further down the line. Without reliable statistical data, it is hard to know how far you can push the speed before that happens.
How does the IS416 help you increase line speed?
The IS416 Sheet Skew Measurement System detects rotated sheets at the coater exit and flags any sheet outside the skew tolerance you set. It also records skew statistics, including the average and the variation (standard deviation), for every batch run.
By comparing these statistics batch by batch, you can see whether sheet control stays stable at a higher speed. That turns line speed optimization from trial and error into a simple, data-driven decision.
How to increase line speed with the IS416: 4 steps
1. Initial assessment
- Run your line at its usual speed for the first batch.
- Use the IS416 to collect the skew statistics for this batch, including the average and standard deviation.
2. Speed adjustment
- Reset the IS416 counter before the next batch.
- Keep the same sheet specification, but increase line speed by about 3%.
- Note the new average and standard deviation at this speed.
3. Progressive optimization
- If sheet control holds at the higher speed, increase speed by another 3% for the next batch.
- Keep increasing speed step by step until a problem appears.
- If a problem appears, reduce the speed slightly until it is resolved.
4. Continuous monitoring and adjustment
- Throughout the process, let the IS416 monitor sheet skew and flag deviations as soon as they occur.
- Make the necessary adjustments based on the real-time data from the IS416.
What results can you expect?
By following this method, many canmakers have increased their line speed by about 7%. That translates into a significant productivity gain of about 800,000 extra sheets without major issues.
How much extra profit can a faster line make?
The table below shows Innosen’s example computation for a lacquering line running 5,000 sheets per hour, with a 3% line speed increase based on IS416 statistical data.
| Source of extra profit | Estimated extra profit |
|---|---|
| Fewer good sheets lost through early detection of faulty sheets | USD 5,000 |
| Fewer good sheets lost through early detection of calamities | USD 1,000 |
| Extra production from faster changeovers | USD 6,000 |
| Extra production from faster line speed | USD 97,200 |
| Total extra profit on the lacquering line | USD 109,200 |
Computation based on a production line running 5,000 sheets/hour with a 3% line speed increase using IS416 statistical data. Actual results depend on your line, sheet prices and production volume.
Conclusion
The IS416 offers a straightforward way to optimize coating line speed while maintaining quality and efficiency. With careful monitoring and incremental adjustments guided by statistical data, canmakers can achieve substantial increases in productivity and profitability with minimal risk.
It’s not just a speed boost; it’s a strategic investment in your profitability and efficiency.
Recommended solutions
- Sheet Skew Measurement System IS416 – protects against poorly placed coating by detecting skewed (rotated) sheets at the coater.
- Sheet Translation Measurement System IS430 MK II – adds protection against laterally displaced coating by detecting sheet misalignment at the coater.
- Sheet Registration Measurement System IS450 – adds protection against poor sheet registration by warning of sheet misfeeds at the coater.
What is the maximum speed your line can run?
Find out with the IS416, or ask us for a profit computation for your own line.
FAQs about coating line speed
How can I increase coating line speed without causing defects?
Increase speed in small steps of about 3% per batch and compare sheet skew statistics after every run. If sheet control holds, continue; if a problem appears, reduce the speed slightly. The IS416 provides the skew data you need for each step.
What is the maximum speed my coating line can run?
It depends on your line and sheets. The safest way to find it is to raise speed step by step while monitoring sheet skew with the IS416 until problems appear, then run just below that point.
What data does the IS416 record?
The IS416 records sheet skew statistics for every batch, including the average and the variation (standard deviation), and flags sheets outside the skew tolerance set by the operator.
How much can line speed increase with the IS416?
Many canmakers using this process have increased line speed by about 7%, producing about 800,000 extra sheets without major issues.
How much extra profit can a 3% speed increase make?
In Innosen’s example computation for a lacquering line running 5,000 sheets per hour, a 3% line speed increase adds about USD 109,200 in extra profit, of which USD 97,200 comes from the faster line speed itself.
Why does sheet skew matter when increasing speed?
Faster sheets are more likely to skew at the coater. A skewed sheet places lacquer on the weld margin, which can cause weld wire breakage, poor welds, spoilage and downtime.
