Key Takeaways
- Barrier coatings inside paint cans play a critical role in preventing corrosion, leaks, and paint defects like skinning.
- Traditional benchtop measurement tools struggled with textured, hard-to-reach surfaces and factory floor constraints.
- Handheld surface energy measurements enabled faster, more repeatable verification directly in production.
- Objective pass/fail criteria helped operators consistently confirm proper coating application.
Monitoring the Application of a Barrier Coating on the Inside of Paint Cans
Surface energy measurements have many obvious uses. Some, however, are less straightforward. In this case, a manufacturer of high-quality consumer paint containers wanted to refine how they verified a critical coating step inside their cans. While their quality standards were already high, they needed a faster and more repeatable way to quantitatively measure surfaces directly on the factory floor.
A key step in the production process involved applying a barrier coating to the inside of the paint container lids and portions of the can interior. This coating acted as a protective layer between the paint and the underlying plastic or metal. Its purpose was to prevent leaking, rusting, denting, and paint skinning. Skinning occurs when paint contacts an exposed, uncoated surface and dries. Once dried, the paint can flake into the container, contaminating the product and negatively affecting adhesion performance.
Initially, the manufacturer relied on a benchtop goniometer to verify coating application. This approach created several challenges. The textured interior of the lids limited measurement accuracy, and the instrument’s size and lack of portability made it impractical for in-line or near-line testing on the factory floor.
Seeking a more efficient and accessible solution, an engineer from the manufacturer turned to Brighton Science and implemented a handheld surface energy measurement instrument. The tool provided a fast, easy-to-use, and repeatable way to evaluate coated and uncoated lids directly in production.
Measurements clearly differentiated coated from uncoated surfaces. Uncoated lids produced contact angles near 80°, while properly coated lids measured closer to 40°. With this data, the manufacturer established objective pass/fail parameters that operators could follow consistently. This removed subjectivity from the inspection process and simplified verification of the coating step during routine production.
As a result, the manufacturer gained a more efficient way to monitor a critical surface condition, helping protect product quality and reduce the risk of downstream defects.
Where BConnect Fits Today
Many manufacturers face similar challenges when verifying coatings, cleaning steps, or surface treatments across shifts, lines, or facilities. While this customer relied on standalone measurements, modern teams increasingly need centralized visibility into surface quality data.
BConnect provides a digital layer that helps teams:
- Capture surface measurement data consistently across production
- Monitor trends and variation over time
- Support quality audits, process validation, and continuous improvement efforts
For organizations scaling surface-critical processes, BConnect helps turn individual measurements into actionable manufacturing intelligence.
Explore BConnect to see how surface data can support smarter quality decisions.
Frequently Asked Questions
Q: Why is barrier coating verification important for paint cans?
A: Barrier coatings prevent corrosion, leaks, and paint defects such as skinning. Inadequate coating coverage can lead to contamination and reduced product performance.
Q: Why did the benchtop goniometer fall short in this application?
A: Textured lid surfaces limited measurement accuracy, and the instrument’s size made it impractical for factory floor use or high-throughput inspection.
Q: How did surface energy measurements improve consistency?
A: Clear differences between coated and uncoated surfaces enabled objective pass/fail thresholds, reducing operator subjectivity.
Q: Can surface measurements be used beyond paint packaging?
A: Yes. Similar approaches are used in industries involving coatings, bonding, sealing, printing, and corrosion protection.
Q: How does BConnect complement surface measurement tools?
A: BConnect aggregates measurement data, enabling trend analysis, traceability, and process control across production environments.