Color Carryover in Tumble Painting: Media Aging and Batch Discipline — 滚涂串色控制：介质老化判定与批次纪律.
A working reference designed to be printed and used at the line. It complements the failure case studies in the Technician Hub with the standard documents those cases eventually produced.
Common Mistakes and How to Avoid Them
| Mistake | Why It Happens | Practical Fix |
|---|---|---|
| 1. Reusing worn media blindly | Worn media marks and carries color | Wear check each unload; top up by rule |
| 2. Random color order | Dark-to-light causes carryover claims | Sequence light to dark; dedicated media per family |
Best Practices
- Media wear card at each drum
- Color sequence posted
- Batch records with media age
Batch Run Sequence
- Media wear check - Size, shape, color load (Worn media marks parts)
- Load per chart - Weight and ratio (Overload stops tumbling)
- Run and record - Cycle time vs chart (Drift signals media aging)
Cards at each drum | Light-to-dark color order
Tumble Line Reference
Media and cycle windows for tumble painting of small parts.
| Parameter | Reference | Why It Matters |
|---|---|---|
| Media/part ratio | Per loading chart | Too little marks; too much hides |
| Cycle time | Per time study | Drift signals media aging |
| Media wear top-up | Per batch count | Keeps finish consistent |
| Color order | Light to dark | Prevents carryover claims |
Media cards ended the carryover claims
Scenario. Light-colored parts picked up dark specks after color changes.
Action. Wear cards per drum and light-to-dark batch sequencing.
Result. Carryover claims stopped; media life became predictable.
Frequently Asked Questions
How do I know media is worn?
Size loss, rounded edges and loaded color. Check every unload against the card.
Why light-to-dark sequencing?
Dark media particles show on light parts. Sequencing prevents carryover without extra cleaning.
What does cycle time drift mean?
Usually media aging or wrong load ratio. Check both against the loading chart.
Implementation Roadmap
| Step | Frequency |
|---|---|
| Media cards live | Every batch |
| Load charts built | Week 1-2 |
| Throughput plan | Month 1 |
What Would You Like to Solve?
If you would like this checklist or template adapted to your own line and part mix, contact QLQ — we supply the full equipment and chemistry package along with the working documents that make it run.