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Precision measurement for coated abrasive manufacturing

In coated abrasive manufacturing—where materials like sanding belts and discs are produced—accurate control of each layer is key to product performance. Despite being commonly called "sandpaper," most coated abrasives today are not made with actual sand or traditional paper. Instead, they consist of synthetic abrasives bonded to advanced backing materials using multiple adhesive layers.

Hammer-IMS delivers contactless measurement solutions that help abrasive manufacturers monitor thickness, basis weight, and density across these layers in real time. Our M-Rays and Edge-Vision-4.0-CURTAIN technologies are ideal for modern abrasive production lines, especially where traditional gauges like beta systems fall short, such as on net-type backings.

1 

Make coat application

The process begins by applying the make coat, an initial adhesive layer, to a flexible backing. Common backing materials include:

  • Paper (engineered and reinforced for durability)
  • PET film
  • Net material (lightweight and breathable, but challenging for traditional sensors like beta gauges)


2

Abrasive grain deposition

Next, abrasive grains such as aluminum oxide are applied to the adhesive layer using an electrostatic deposition process. The electrical charge aligns the grains vertically, optimizing cutting efficiency and product longevity.

3

Size coat application and curing

The size coat, a second layer of adhesive, is applied to secure the abrasive grains in place. After this step, the material is dried and cured under controlled temperature and humidity.

Inline surface inspection with Edge-Vision-4.0-CURTAIN

The Edge-Vision-4.0-CURTAIN system provides inline visual inspection by detecting coated vs. uncoated areas across the web. Positioned after abrasive grain deposition, it calculates the filling degree to assess coating uniformity, ideal for monitoring open- and closed-coat products. A second unit can be placed at the end of the line for final inspection, detecting coating defects and verifying edge coverage.

Measuring thickness, density and basis weight with M-Rays

  • Basis-weight is measured directly after each coating step, such as the make coat or size coat application. This gives immediate feedback on how much adhesive or abrasive material is applied per square meter.
  • Thickness is typically measured after drying or curing, once the layer has stabilized. This helps verify the physical build-up of coatings like the make coat, size coat, or total layer stack.
  • Density is calculated when both thickness and basis weight are known, often after curing. This provides insight into the consistency and compactness of the applied layers, especially the abrasive grain section.

This makes M-Rays a powerful all-in-one solution for monitoring coated abrasive materials during production—without the use of ionizing radiation.

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