Heating System with inbuilt Intelligence

Thermal treatment is vital processing step in any kind of product processing systems across various industries such as Pharma, Food, Chemical, Fertilizers, Coating, Paint, Ceramic, Electronics and many more. Application of heating system such as heating, drying, sterilization, coating, pasteurization, blanching, mixing and many more; all requires very preciously controlled heating for quality production. But as we all know, every material put under processing may or may not have the same level of moisture or may not require same temperature for processing though being the same type if material also manually adjusting the heating temperature or heating time is also not feasible; Practically!

We as Kerone, have always advocated that the new age thermal treatment systems must be capable of making efficient decision to offer best possible correction based of the input material type its contents and behavior while under processing. This shift is paradigm in industrial thermal treatment from brainless to brained industrial desired. This might have been not possible few decades back however due to advancement of AI, ML and IoT technologies it is achievable to large extend.

Advanced AI and ML can make machines more intelligence with by building the capabilities such as:

Computer Vision:

Precisely trained deep learning model that can detect the minute deflection in the product quality which is even the most experienced workmen cannot find. Cameras are very sensitive compared to human eyes and they can be installed within the machine to detect the flaw within the product under process and take corrective actions. This will be possible by combining the AI and ML together detect early and correct properly.

Digital Twins:

Digital Twins is concept that leverages the power of all three AI, ML and IoT together and help you to be with the machine every time even you are away. Digital twins are exclusively useful when working with equipment from a remote distance. Sensors implanted inside machine gathers data about real-time status, working condition or position and this data can be access via internet and cloud from processing and providing information on your figure tip.

Speech and Text Recognition:

It gets hard to modify the temperature, wind current, speed and so on to the exact an incentive for the ideal yield quality when did physically. With the capacity to identify discourse and content you can converse with new age machines and impart what is required. Some time you don’t have a clue what parameter will bring about best quality handled item, anyway with the AI and ML simply address machine or feed the necessities, it will change over that contribution to the parameters that will be required for best outcome and modify all the hardware to work and accomplish the shared objective.

Predictive maintenance:

Preventive maintenance is not old school thing in contradicted to that we have predictive maintenance. As the machine continuously reports for minute by minute performance is recoded and AI and ML models detects the potential fault and inefficient performances in advance. The AI and ML powered predictive maintenance saves businesses valuable time and resources, including labor costs, while guaranteeing optimal manufacturing performance.

Advantages of system with power to help in making decision:

  • Less Wastage of material.
  • Less and efficient utilization of energy.
  • Fast and precise heating system.
  • Save energy in some case up to 50%.
  • Easy integration with modernized production lines.
  • Understand, monitor, predict and control process variability.
  • Augment equipment and process diagnostics capabilities.
  • Quicker Response time and less operations cost for machine with inbuilt intelligence.
  • Real-time remote monitoring of performance.
  • Multi-site monitoring improving the operational efficiency and reducing the site downtime.
  • Full manufacturing traceability.
  • Predictive Maintenance and quality management.

A Catalyst to Longevity of your Product–Industrial Coating

Coating is a covering applied to a product usually referred to as the ‘substrate’ with a layer of liquid or powder. It is done either for decorative or protective purpose or even both. Coating may be all-covering or may also cover some parts of the substrate.
There has been an increasing demand for industrial coating in the market. Industrial coatings are essentially specialized paints that are used for protective and functional purposes, to resist corrosion and destruction from dust and other materials thus increasing the longevity of the product and enhancing its functions. Coating helps the substrate to achieve a desired level of strength, surface tension and a perfect finish.
Coating is used on the following materials or products:

  • Pharmaceutical Tablets: are coated to confer specific benefits; that broadly range from facilitating product identification to modifying drug release from the dosage form.
  • Food Items: are coated for various purpose namely; adding nutritional value, enhancing taste and longer preservation.
  • Metal Equipments: are coated for durability, to reduce wear & tear and protection against corrosion.
  • Wooden Furniture: are coated for it provides durability, rich colour and minimizes hazards.
  • Glass: is coated for protection from mechanical and chemical stress, increased scratch resistance and shatter protection and also for beautification.
  • Textile/Fabric: is coated for superior heat protection, exceptional durability and resistance to chemicals and abrasion.
  • Paper: is coated to give water resistance and wet strength to the paper or to protect against ultraviolet radiation.
  • Plastic: is coated for resistance from heat and for rough & tough features to last long.

Types of Coating:

  1. Powder Coating – Powder coating is a multi-step finishing process.
    i: The product is cleaned and prepared for coating.
    ii: It is coated with a fine powder. The powder covers the product’s surface.
    iii: The product is then moved into a curing oven, to get heated, allowing the powder to melt and flow into a uniform coating that adheres to the product, creating a very durable and attractive coating around the product after the melted powder cools and hardens.
  2. Liquid Coating – Liquid paint coating is the simple application of paint to products, with the help of various machineries.
  • We, at KERONE hold the expertise in designing, manufacturing and installing of custom built immersion/Dip Coating systems, which are available in free-standing floor or tabletop models, these are specifically designed for production applications that do not require large in-line systems.
    Following are our various types of coating plants and lines:
  • Gravure Coating Machine
  • Reverse Roll Coating Machine
  • Knife-Over-Roll Coating Machine
  • Air Knife coating
  • Metering Rod (Mayer Rod) Coating Machine
  • Slot Die Coating Machine
  • Curtain Coating Machine
  • Immersion/Dip Coating Machine
  • Hot melt Coating Machine
  • Web Coating Machine
  • Fabric Coating Machine

Why choose us?
Accuracy, efficiency, machine quality and output quality are not just words but our commitment towards our profession since last 42 years, creating a base of more than 1000 loyal customers. Kerone coating systems can be used to apply a range of coatings, as well as photo-resists and solder masks that are part of the printed circuit board applications – all with a level of precision that manufacturers demand. We also provide detailed assistance without much hassle of complex functioning of the machinery. We always strive to achieve more than client satisfaction with our timely delivery, quality and efficiency towards every machine manufactured by us.

Making You Dose of Tablet Consumable- Table Coating

Tablets consist of active ingredients and excipients in the form of solid dosage. Now days we can find tablets in many varying shapes and sizes few are very attractive to but precise care is taken while manufacturing. Tablets are preferred worldwide due to its ease of consumption and carrying capacity.
Coating of tablet is done to achieve functional improvements like:

  • Improve the handling capacity
  • Make the tablet packing and transportation easy
  • Helps in improving life of tablet and maintaining the shape
  • Protects the ingredients and excipients
  • Control the release of drug in intestine

As per the book of Grahem Cole, John Hogan and Michael Aulton Title “Pharmaceutical Coating Technology” below are few more interesting reasons ‘Why Coating Tablet?’: The core contains a substance which imparts a bitter taste in the mouth or has an unpleasant odour.

  • The core contains a substance which is unstable in the presence of light and subject to atmospheric oxidation, i.e. a coating is added to improve stability.
  • The core is pharmaceutically inelegant.
  • The active substance is colored and migrates easily to stain patient’s clothes and hands.
  • The coated tablet is packed on a high-speed packaging unit. The coating reduces friction and increases the production rate.
  • To modify the drug release profile, e.g. enteric coating, sustained release coating, osmotic pumps, etc.
  • To separate incompatible substances by using the coat to contain one of them or to coat a pellet which was previously compressed into a core?

Tablet Coating is defined as a process by which an essentially layer is applied. The process of coating involves primarily 3 components or Stages: –

  1. Raw tables chemical property
  2. Solvent/Solution which will be on the Tablet
  3. Coating Equipment

There are 3 main type of coating processes:

  • Sugar coating:

The various sequential steps involved in sugar coating are:

  1. Sealing
  2. Subcoating
  3. Smoothing
  4. Colour Coating
  5. Polishing
  6. Printing
  • Film coating: 

A film coating is a thin polymer-based coat applied to a solid dosage form such as a tablet, granule or other particle. The thickness of such a coating is usually between 20 and 100 µm.
Film-coating formulations usually contain the following components:

  1. Polymer
  2. Plasticizer
  3. Pigment/opacifier
  4. Vehicle
  • Enteric coating:

The properties of enteric coating material are:

  1. Compatibility with most of the coating solutions
  2. Non toxicity.
  3. Low cost.
  4. Ease of application
  5. Formation of continuous film
  6. Resistant To gastric fluids.

We try taking up one by one technique in details in upcoming blogs, We at KERONE as involved in providing quality engineering solution to various pharmaceutical organization.

Understanding Coating and Techniques of coating!!!

A coating is a process in which layer of polymer or any material in liquid form used for depositing or covering the surface of the substrate. As per the Wikipedia the purpose of coating is decorative, functional or both. Decorative coating is done to achieve the aesthetic look and feel of material i.e. coating or painting on the fabrics with some artistic manner, on the other hand functional coating is applied achieve the adhesion, wetability, corrosion resistance, wear resistance, or water resistance.
The science of coating requires the understanding of the two phenomenon liquid flow and surface chemistry that deals with the solid to liquid relations. Study of viscosity and changed in the shape of liquid is very important in the process of coating.
Coatings are defined as mixtures of various materials. The materials are classified into four categories:

  • Resins
  • Pigments
  • Solvents
  • Additives

Techniques of the Coating:
Various coating techniques help in achieving the coating width of from thickness of some microns to mm, various coating techniques are as follows:

  • Gravure Coating Machine
  • Reverse Roll Coating Machine
  • Knife Over Roll Coating Machine
  • Air Knife coating
  • Metering Rod (Mayer Rod) Coating Machine
  • Slot Die Coating Machine
  • Curtain Coating Machine
  • Immersion/Dip Coating Machine
  • Hot melt Coating Machine
  • Web Coating Systems
  • Fabric Coating Machine

You can ask the experts such as KERONE those are pioneer in manufacturing and designing of various type of the coating machines and plants. We can be reached at info@kerone.com .


Paper Coating Machine

The paper and paper products plays more substantial role in the day-to-day life of the human, its usage are increasing every day in as newspapers, magazines, envelopes, books & diaries, stationeries, packaging and etc. the usage of paper and paper related products have become nearly unlimited. The increasing application has increased the demand of quality paper, majorly the paper quality is defined in terms of its smoothness, glossy finish, printability, uniform thickness and moisture contain.
The increasing demand of the paper the manufacturers wanted to have the paper manufacturing machines to produce higher quality paper, increase productivity, reduction in the waste, safe and improved process control. The paper manufacturing and paper coating process is known as one of the major dewatering process, which requires removal of all even a small amount of water also by the way of evaporation for the quality paper and coatings. The paper machine consist of the four sections Forming Section, Press Section, Drying Section, Calender Section. Wikipedia explains the sections as follows:

  • Forming section, commonly called the wet end, is where the slurry of fibres filters out fluid a continuous fabric loop to form a wet web of fibre.
  • Press section where the wet fibre web passes between large rolls loaded under high pressure to squeeze out as much water as possible.
  • Drying section, where the pressed sheet passes partly around, in a serpentine manner, a series of steam heated drying cylinders. Drying removes the water content down to a level of about 6%, where it will remain at typical indoor atmospheric conditions.
  • Calender section where the dried paper is smoothened under high loading and pressure. Only one nip (where the sheet is pressed between two rolls) is necessary in order to hold the sheet, which shrinks through the drying section and is held in tension between the press section (or breaker stack if used) and the calender. Extra nips give more smoothing but at some expense to paper strength.

The most critical part of the paper making process is drying the paper post press section to leave around 6% of the moisture contain within paper, hence the selection of the dryer and drying technology plays very vital role in total paper production system. In the dryer section, the paper entanglement passes over rotating; a cast iron cylinder which was heated by the means of heat transfer mechanism such as Convention, Conduction and/or Radiation and the most of the remaining water is removed by evaporation. When the paper leaves the dryer section its solid content has increased to about 90-95%. Thermal energy transferred from the heater is used for the dewatering of the paper in the dryer section.
Since the drying is critical in the entire paper production process as overlooking its criticality by the paper manufactures and/or plant operators may results in improper paper quality of paper, increased waste and reduced production. Hence the choice of the drying technology and dryers needs to be done properly by consulting with the leaders in the field of heater and heating technologies such as KERONE.
KERONE has been serving the paper and other manufacturing processes with its quality and technically superior innovative product quality since last 40 years. We at KERONE is have team of experts to help you with the your need of heating system from our wide experience. For any query write us at info@kerone.com .