EISENMANN · The first European plant for EC priming and powder coating of fully welded truck...
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Powder Coating EISENMANN
Transcript of EISENMANN · The first European plant for EC priming and powder coating of fully welded truck...
Powder Coating
EISENMANN
Contents
Advantages of Powder Coating 1
Powder Coating Lines from a Single Source 2
Glass Powder Booths 4
Powder Booths with Filter Recovery 5
Booths with Cyclone Separation 6
Changing Colors 7
Cleaning and Pretreatment 8
Material Flow Automation 9
Powder Curing Ovens 10
Real-World Examples 11
Service and Maintenance 12
Continuously providing new designs, EISENMANNis the trend-setter in surface technology. Example: the glass booth(above) or powder lines for the automobile industry.
EISENMANN is among the leading worldwide manufact-urers of complete coatinglines. We work with the mostadvanced technologies andexperience gained over thedecades from several hundredreal-world paint lines.
EISENMANN is the expert partner for future-oriented surface technology in all areasof industrial coating, from jobcoaters to the automobileindustry.
Working in small teams, ourengineers collaborate with specialists in environmentalengineering, conveyance tech-nology, and control technologyto develop individual systemdesigns.
We demonstrate our competen-ce in more than just equipmentdesign. As operators of comp-lete painting facilities for theauto industry, we are respons-ible through our own personnelfor economic facility operationand the highest surface quality.
EISENMANN Technology and Know-how:
EISENMANN Powder Coating Systems.
The first ever overhead powder top coat line for the the automobile industry from EISENMANN.
Convincing Advantages
The advantages of powder coating compared to othercoating processes are convin-cing:
> Virtually loss-free coating by means of overspray recovery.
> High-quality coating with an extremely scratch-resistant, shock-resistant, and corrosion resistant surface.
> No exhaust air problems, no paint sludge.
> Easy to automate.> Coating thickness of
40 to 200 m (1.5 to 8 mils)are possible in one coating.
Over time, companies of allsizes and from all fields havemade good use of these advant-ages. Now the auto industry -trendsetter in terms of quality,economy, and environmentalcompatibility - has also joinedthe ranks of those using powder applications with equipment from EISENMANN.
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Color Selection no Problem
Advanced powder booth andcustom system designs makepossible economic operationsand a high degree of flexibilityeven for users who changecolors frequently. EISENMANNhas the right system for everyuse: powder booth with filterrecovery, cyclone separation, or combined systems for bothmethods.
Perfect Fit
Turnkey - all equipment components in perfect harmonywith each other - that’s yournew powder coating line from EISENMANN:
Water-saving pretreatment,powder booth made of glass orstainless steel, energy-savingovens, efficient material flowsystems, and advanced con-trols. EISENMANN has its ownin-house experts for all ofthese areas of concern. So you only need a single party to answer all your questionsregarding the implementationof your new powder line.
Advantages from Custom Solutions:
The Complete Powder Coating Line from a Single Source.
EISENMANN delivers automatic and manually-operated powder booths for all application systems..
Today’s coating lines are integratedin the production flow, reduce emiss-ions and wastewater. Together with EISENMANN, this manufacturer ofmailbox systems in the photograph on the left has implemented state-of the art coating facilities at variouslocations.
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In order to obtain first-class surfacequality, the workpieces must undergoa perfect pretreatment which is specifically laid out for your parts.
Fancy controls for appliances(above): All process parameters can be displayed and altered on the viewing screen on the control panel.Diagnostics can be conducted in thesame manner.
Flexible material flow systems, like EISENMANN’s Power & Free Conveyor, organize the productionflow and connect the coating process to the production processesboth upstream and downstream.
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Transparent in Every Respect:
Powder Booths Made of Glass.
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Transparent in every respect:EISENMANN has created powderbooths made of glass. Specialsafety glass and walk-on stain-less type steel floorshave proven their value inreal-world operations.
The Advantages of Glass Booths
> Less powder adhesion than in conventional booths because the booth walls cannot be electrostatically charged.
> Super-smooth surface, very good for cleaning.
> The ideal workspace for the manual coater. The transpa-rent booth is easy to see into and permits personnel to have visual contact with the work environment. Because of the well balancedelectrostatic conditions, the powder cloud goes directly onto the workpiece (instead of onto the coater).
Clean Floor, Best Surface Quality
Best coating quality is achieved when there is littlepowder in circulation.
This is why an automatic floorsweeping system is integratedinto EISENMANN powder booths; it conveys overspraypowder, that has not reachedthe recovery system, into thereservoir.
This is how the floor sweepingsystem, in conjunction with the powder recovery system, forwards all of the overspray immediately back into the powder circulation system.
Clean Air without Losing Powder:
Powder Recovery with Filter Systems.
Powder booths with filter recovery have proven them-selves in the most strenuousreal-world conditions.
Powder booth, recovery, and filters form a unit in which the complete recovery systemcan be exchanged dependingon the color desired. The filteris cleaned automatically duringongoing operations, the exhaustair is returned directly to thehall as circulating air.
The AdvantagesPlastic Filter:Highest degree of separation,high mechanical stability, easy to clean.Better Air Flow:Horizontal powder cloud withbetter wrap-around.Short Powder Paths:Reservoir is directly below the filter!Rapid Color Change:Detachable recovery units,movable powder booths orautomatic filter cleaningsystem.Easy Operation:All units requiring maintenanceare accessible and controllableduring operation (i.e., sievemachines, reservoirs, etc.).
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This manufacturer of radiators usesthe glass booth with performance plastic filter..
EISENMANN
Powder reservoir Fluidized bed
ConveyorPowder booth
made of glass orstainless steel
Reciprocatorwith guns
Refillopening
Powder sieve
Inspectionhatch
Powder filtermade of sintered plastic
Housing unitwith filter blow-off unit
For Many Colors and Small Series:
Powder Recovery with Cyclone Separation.
Intermediate powder container for conveying powder over longdistances for high powder through-put.
Powder booths with cyclone separation (mono- and multiple-cyclones) are ideal for distinctmany-color coaters. In general,the cleaning of the separatorsystem in cyclone booths is simpler than in filter booths, although the powder loss is higher.
The exhaust air travels horizon-tally through side openings intothe cyclone. The recovered powder is transferred through a conveyor and a sieve into themain reservoir.
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This manufacturer coats aluminumprofiles and facades in many specialcolors in an EISENMANN powderbooth with a mono-cyclone.
EISENMANN
Sieve machine
movablemultiplecyclone to
absolutefilter
Conveyor
Vibrator forpowder container
Reciprocator with guns
Powder booth madeof glass or stainlesssteel
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From Black to White:
Implementing Colors Changes.
The right fit in color change design is a requirement for efficientoperations for job coaters with frequent color changes. EISENMANNoffers individual solutions with its movable powder booths and different recovery systems.
Shown in the diagram: designs for rapid and economic color
changes with two or more movable powder booths with
filter recovery systems.
The following criteria areimportant in terms of goodcolor changing concepts:
> Frequency of color change and production time per color.
> Percentile distribution of colors to be processed.
> Number of colors to be processed.
> Capacity and utilization of the system.
When throughput is not veryhigh and the color is only changed every few days, a single additional recovery unit generally suffices.
Frequently several movablepowder booths are used when there are high levels of throughput with standardcolors and additional specialcolors.
When a booth is off-line, thecolor is changed by exchangingthe complete recovery unit orby cleaning the filter in thespecial automatic cleaningsystem. Booths with cycloneshave proved worthwhile forvery frequent color changeswith small production runs.
Diagram below: High rates of throughput and many colors requireseveral partial powder lines that have different recovery systems.
Powder line 1Standard colors
Filter booth 1
Booth 1
Booth 2 Filter booth 2 Cyclone chamber
Powder line 2Standard colors
Powder line 3Special colors
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High Quality and Practical Environmental Protection:
Cleaning and Pretreatment.
EISENMANN’s advanced pre-treatment equipment savesfresh water and wastewater, isenvironmentally friendly, andensures the greatest surfacequality.
Maintaining and extending thelife of process and rinse bathsis not just economical, but italso makes environmentalsense.
So today rinse water is usedmultiple times using counter-flow or recycling techniques.Life for cleaner baths can beincreased substantially by dividing into multiple zones or by using continuous oilseparators.
Further standardized conceptsare available for extending theservice life and are optimallyselected by EISENMANN inaccordance with the applicat-ion in question.
When the throughput is not allthat high, a wastewater-freepretreatment utilizing an evaporator is an interestingalternative. No water goes tothe drain; any distillate flowsimmediately back into thesystem.
Schematic of effluent-free pretreatment.
Spray pretreatment with numerous options for bath maintenance.
Degreasing I Degreasing IIRinsing I DI rinsingRinsing II
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Ideal in coating and painting operations are destination
controlled, flexible and robustPower & Free systems.
Gantry robots connect different conveyor systems in a wheel coating operation. The robot transfers the just-powdered wheelsfrom the spindle conveyor to the chain-on-edge conveyor of the powder curing oven.
Overhead conveyors, Power&Free conveyors, skid conveyors,programmed hoist systems, liftstations, transfer mechanismsand specifically developed special conveyors are fine-tuned to the workpieces andthe operation.
Handling devices or gantryrobots are available for connecting different conveyorsystems and for workpiece loading and unloading.
Everything in Motion:
Material Flow Automation at the Highest Level.
EISENMANN develops in-housethe complete material flow and control technology for automatic coating lines.
We work out the best solutionfor you individually in terms of efficient production flow, greatest operational reliability,and highest degree of economy.
Economical and Energy-Saving:
Powder Ovens, Any Style.
EISENMANN curing ovens aredesigned for high efficiency and the best surface quality.Continuous ovens with singleor multiple passes or blockarrangements with the waterdry-off oven are heated direct-ly or indirectly with oil, gas, electricity or recovered energy.
The structures range fromfloor-mounted single chamberovens to elevated multiplepass ovens with energy-savingbottom entry/exit and optimi-zed heating designs.
There are infrared ovens forworkpieces with temperaturesensitive components or highmaterial thicknesses. Infraredovens are also frequentlyemployed as pregel zones forconventional convection ovensbecause of their excellent cross-linking effect on powder.
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Combined water drier and powder oven with IRM emitters and air recirculation for aluminum wheels.
Powder oven
Water drier
Circulating air duct
Circulating air duct
Circulating air duct
Circulating air duct
Circulating air duct
Circulating air duct
Melting phase with IRMemitters
Four Possibilities, out of a Hundred:
Real-World Examples.
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This company offers its customers lighting systems in a great variety ofcolors. Using the new EISENMANN powder line, it is economical to processstandard colors in large lot sizes and special colors in small batches.
Heaters are increasingly delivered in fashionable colors. With two automaticbooths for standard colors, 1 automatic booth having 6 recovery units forspecial colors, and one manual booth for small production runs and indivi-dual pieces, this manufacturer has ensured his competitiveness far into thefuture.
The first European plant for EC priming and powder coating of fully weldedtruck chassis was planned and built by EISENMANN. After electro-coating,the workpieces weighing up to 6 tons each are top coated in one of thethree powder coating booths.
Complete powder coating plant with Power&Free system for compressorhousings.
The EISENMANN Service offers an extensive range of services.These are tailored individually to the customer's needs, there-by taking the know-how of the customer's employees, the coststructure, the processes andthe need for expertise into consideration.
Therefore, we regard ourselvesas system providers when itcomes to meeting the individ-ual customer's requirements.
Maintenance Management
• InspectionWe determine the actual stateof your system by conductinginspections and then informyou about the weak spots andpossibilities for increasing yourperformance, or let you know ifthere is an urgent need to takeaction.
• ServicingIn order to determine the tar-get state of your system, ourspecialists not only conductthe servicing, but also carryout mechanical and electricalcheck-ups and safety tests.Routine servicing guaranteesan optimum functioning ofyour system and increases itsservice life.
• RepairOur maintenance team alsocarries out any necessaryrepairs and component replace-ments of course.
• Remote System DiagnosisUsing remote data communic-ation, the remote system diag-nosis enables our specialists to access your controls andmaterial-flow computers quick-ly and easily, and remedy anyfaults within the shortest time.
Service and Maintenance
On-call Service
We offer you a 24/7, on-callservice conducted by our Service specialists, which isbased on a mutually agreedresponse time and customisedto your own specific shiftoperation and productiontimes.
Service Contracts
• Maintenance ContractsYou can rely on EISENMANNService. We offer you custo-mised Maintenance Contractsfor your system. You arereminded in good time of the next routine service whichis carried out by qualifiedengineers. This enables you to plan the costs on a contin-uous basis and reduce the system downtimes by takingpreventative measures.
• Full ServiceDue to our excellent experi-ence gained in the construc-tion and operation of highlyautomated industrial systemsand factories, we are able totake over the entire mainte-nance of your system, allowingyou to fully concentrate onthe key processes of your business. We guarantee systemavailability at all times, andthe value of your systems ispreserved long-term through:
• Preventative maintenance• Troubleshooting • Repairs
• System ReconstructionsThe EISENMANN Service is yourfirst contact for system recon-structions or extensions,whether for paint-spraying andenvironmental technology, orfor process technology and
materials handling. We adaptyour systems engineering tonew conditions if, for example,you should wish to increaseyour throughput, or the product dimensions or weightshave changed, or if your spaceplanning necessitates this. We likewise offer you a firstclass service where productionrelocation is concerned.
• UpdatesModernisation or conversionsto new systems require modifi-cation measures, such asreplacing controls, softwareand hardware updates, forexample. Our specialists, withtheir high level of expertise,are available at all times.
Process Optimisation
We also offer you advice, of course, when it comes to opti-mising your production orimproving it on a continuousbasis. We place applicationand process specialists at yourdisposal who thoroughly ana-lyse your processes and findout where the weak spots are.
In close liaison with youremployees targets and mea-sures for optimisation andplans of action are defined.Key issues can, for example,include quality problems, cost-saving potential and prevent-ative maintenance concepts.
Run-up Support
With its “standby” conceptEISENMANN offers individualsupport on site. Excellentlyqualified EISENMANN staffsupport your personnel byaccompanying the productionat start-up and also during theproduction. Your personnel arenot left to their own deviceshere; they have direct accessduring the operations to the“standby” staff who step inwhen the situation becomescritical.
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EISENMANN Corporation150 East Dartmoor DriveCrystal Lake . Illinois 60014 . USAPhone +1 815 4554100Fax +1 815 [email protected]
EISENMANN do BrasilAvenida Duquesa de Goiás, 7163° andar . Bairro Real ParqueCEP: 05686-002 São Paulo SPPhone +55 11 21611200Fax +55 11 [email protected]
EISENMANN S.A. DE C.V. MexicoBlvd. 15 de Mayo 2933Fracc. Las Hadas72070 Puebla, Pue.Phone +52 222 2311712Fax +52 222 [email protected]
EISENMANN Shanghai Co. Ltd.Room 301, Gubei Intern. Fortune CenterNo. 1452, Hong Qiao RoadChangning DistrictShanghai 200336 . P.R. ChinaPhone +86 21 31352188Fax +86 21 [email protected]
OOO EISENMANNUl. Pyatnitskaya 47-1119017 MoscowRussian FederationPhone +7 495 951-6824Fax +7 495 [email protected]
EISENMANN India Pvt. Ltd.EISENMANN Surface Finishing SystemsIndia Pvt. Ltd.Technosoft Knowledge Gateway · 1st FloorPlot No. B-14 . Road No. 1Wagle Industrial EstateThane (W) 400 604 Maharashtra . IndiaPhone + 91 22 2583 2929Fax + 91 22 2583 [email protected]
EISENMANN Anlagenbau GmbH & Co.KGTuebinger Strasse 8171032 Boeblingen . Germany
Daimlerstrasse 571088 Holzgerlingen . Germany
Phone +49 7031 78-0Fax +49 7031 [email protected]
EISENMANN Service GmbH & Co.KGTuebinger Strasse 8171032 Boeblingen . GermanyPhone +49 7031 78-3000 (6.30 - 18.30 h)Fax +49 7031 [email protected]
EISENMANN Ingeniería S.A. Parc de Negocis Mas BlauEdificio Prima Muntadas c/Berguedà, 1 . Barcelona08820 El Prat de LlobregatPhone +34 93 479-6610Fax +34 93 [email protected]
EISENMANN France S.a.r.l.Espace Lumière . 2, Rue Pathé 78406 Chatou CedexPhone +33 1 30159800Fax +33 1 [email protected]
EISENMANN Italia S.r.l.Via Ferrari, 2121047 Saronno (VA)Phone +39 02 96718-626Fax +39 02 [email protected]
EISENMANN U.K. Ltd.Unit 118 Severn HouseAnson Court Business CentreStaffordshire Technology ParkBeaconside . StaffordStaffordshire ST18 OGBPhone +44 1785 283790Fax +44 1785 [email protected]
www.eisenmann.com
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