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Calcimator

E-Coat Bath Calculator

Calculate electrocoating bath parameters including film build, current requirements, paint consumption, and energy costs for cathodic e-coat systems.

Inputs

%

Results

Predicted DFT (mils)

0.03

Daily paint usage (gal)

26.6

Average current (amps)133.3
Current density (ASF)4.44
Power per part (kW)33.33
Energy per part (kWh)1.11
Paint per part (gal)0.06
Daily energy (kWh)533.3
Heat generated (BTU/hr)113,733
Throwing power (1-10)6.9
How to Use This Calculator
  1. Enter Part surface area (sq ft), Target DFT (mils), and Bath voltage (V).
  2. Set Bath solids (%), Immersion time (sec), and Bath temperature (°F).
  3. Adjust Parts per hour as needed.
  4. Review Predicted DFT (mils) and Daily paint usage (gal).
  5. Use Average current (amps) and Current density (ASF) to inform your decision.

How the result changes with Bath solids (%)

Bath solids (%)Predicted DFT (mils)Daily paint usage (gal)
120.0239.9
150.0331.9
200.0424
240.0420

What each input means

Part surface area (sq ft)
Total immersed surface area of the part.
Target DFT (mils)
Target dry film thickness. Typical automotive: 0.6-1.2 mils.
Bath voltage (V)
Applied DC voltage. Higher voltage = thicker film and better throwing power.
Bath solids (%)
Paint solids content of the bath. Typical: 15-22%.
Immersion time (sec)
Time the part is immersed and energized.
Bath temperature (°F)
Operating bath temperature. Optimal: 80-90°F.
Parts per hour
Production throughput rate.

What each result means

Predicted DFT (mils)
Estimated dry film thickness at these settings.
Average current (amps)
Average rectifier current per part.
Current density (ASF)
Average amps per square foot.
Power per part (kW)
Electrical power during coating.
Energy per part (kWh)
Total energy consumed per part.
Paint per part (gal)
Paint consumed per part.
Daily paint usage (gal)
Total paint consumed per 8-hour shift.
Daily energy (kWh)
Total electrical energy per shift.
Heat generated (BTU/hr)
Heat load requiring chiller removal.
Throwing power (1-10)
Higher = better coverage of recessed areas.

How this is calculated

Worked example, using the default values

  1. Identify Input Parameters
    4 parameters
    Part surface area (sq ft) = 30, Target DFT (mils) = 0.8, Bath voltage (V) = 250, Bath solids (%) = 18 = 7 input(s) provided
  2. Calculate Predicted DFT
    Predicted DFT = k * sqrt(bathVoltage) * (bathSolidsPct / 100) * pow(immersionTimeSec / 60, 0.4)
    0.032 = 0.032
  3. Calculate Daily paint usage
    Daily paint usage = paintSolidsPerPartGal * partsPerShift
    26.6 = 26.6
  4. Calculate Average current
    Average current = avgCurrentDensityAsf * partSurfaceAreaSqFt
    133.3 = 133.3
  5. Calculate Current density
    Current density = 8 * (bathVoltage / 250) * (1 / (1 + targetDftMils))
    4.44 = 4.44

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