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Calcimator

Dip Coating Calculator

Calculate dip coating film thickness, paint consumption, and drain time for industrial immersion coating processes.

Inputs

%

Results

Dry film thickness (mils)

0.47

Daily paint usage (gal)

1.1

Wet film thickness (mils)1.04
Paint per part (gal)0
Drip return per part (gal)0
Drip return (%)30
Drain time (sec)50
Total cycle time (sec)320
Tank turnover (days)276.5
Daily Solids (gal)0.49
How to Use This Calculator
  1. Enter Withdrawal speed (in/min), Viscosity (cps), and Volume solids (%).
  2. Set Coating density (lb/gal), Part surface area (sq ft), and Tank volume (gal).
  3. Adjust Parts per hour as needed.
  4. Review Dry film thickness (mils) and Daily paint usage (gal).
  5. Use Wet film thickness (mils) and Paint per part (gal) to inform your decision.

How the result changes with Volume solids (%)

Volume solids (%)Dry film thickness (mils)Daily paint usage (gal)
190.21.1
420.441.1
690.711.1
910.931.1

What each input means

Withdrawal speed (in/min)
Speed at which parts are withdrawn from the coating bath.
Viscosity (cps)
Coating viscosity in centipoise.
Volume solids (%)
Volume solids percentage of the coating.
Coating density (lb/gal)
Weight of coating per gallon.
Part surface area (sq ft)
Surface area of each part.
Tank volume (gal)
Total tank volume in gallons.
Parts per hour
Throughput rate in parts per hour.

What each result means

Wet film thickness (mils)
Predicted wet film thickness at withdrawal.
Dry film thickness (mils)
Predicted dry film thickness after cure.
Paint per part (gal)
Net paint consumed per part.
Drip return per part (gal)
Excess coating that drips back to tank.
Drip return (%)
Percentage of applied coating that drips off.
Drain time (sec)
Recommended drain time before curing.
Total cycle time (sec)
Immersion + withdrawal + drain time.
Daily paint usage (gal)
Total paint consumed per 8-hour shift.
Tank turnover (days)
Working days to consume one full tank volume.

How this is calculated

Worked example, using the default values

  1. Identify Input Parameters
    4 parameters
    Withdrawal speed (in/min) = 6, Viscosity (cps) = 200, Volume solids (%) = 45, Coating density (lb/gal) = 10 = 7 input(s) provided
  2. Calculate Dry film thickness
    Dry film thickness = wftMils * (volumeSolidsPct / 100)
    0.47 = 0.47
  3. Calculate Daily paint usage
    Daily paint usage = effectiveWetVolumeGal * partsPerShift
    1.1 = 1.1
  4. Calculate Wet film thickness
    Wet film thickness = k * sqrt(viscosityCps) * pow(withdrawalSpeedInMin, 0.6)
    1.04 = 1.04
  5. Calculate Paint per part
    Paint per part = wetVolumeGal * (1 - dripLossPct / 100)
    0.0045 = 0.0045

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