Fully automated, cost-effective painting processes

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High levels of cleanliness on the production line

Doris Schulz

Cleaning solutions need to be carefully coordinated in order to meet high standards for the removal of contaminant films and of particles in the single-digit micrometre size range and below and to fulfil these requirements reliably as part of a volume production process. There are a number of important criteria to be considered in this respect. PDF-Download

Aqueous cleaning process with solvent-based corrosion protection

Josef Klabuschnig

A supplier to the automotive industry invested in a multi-chamber immersion machine in order to increase its capacity and the quality of its cleaning processes. The new machine can clean steel parts with complex shapes in short cycles using an aqueous process and can also apply a solvent-based corrosion protection solution. PDF-Download

Optimising thermal paint stripping processes

Igor Rogowski

In order to maintain the surface quality of large components during coating removal, the individual stages of the process must be carefully analysed. Computational fluid dynamics can then be used to improve the process and reduce costs. PDF-Download

Combining quality and flexibility

Michael Seeger

Solarlux, a manufacturer of glass folding doors and glass extensions, has been powder coating its aluminium profiles in-house at its new site for the last year with the aim of improving the quality of its products even further and cutting the costs of production. A new and highly flexible power-and-free conveyor system ensures a smooth flow of materials. PDF-Download

Mimicking and combining different surfaces

Karl Bubenhofer AG

A new powder coating system for facades mimics different types of surfaces and therefore also allows them to be combined easily. The system opens up new design opportunities and applications, while also being highly resistant to light and weathering. PDF-Download

What security is offered in practice by standardised test procedures?

Hans-Jürgen Alfort

Test methods for the continuous production control in the powder coating must deliver results as quickly as possible. In the following article important tests are rated for process monitoring in terms of significance to the user. PDF-Download

Monocyclone reduces energy and powder consumption

J. Wagner GmbH

The biggest energy consumer in the powder coating process is the fan motor in the final filter. However, the use of a cyclone with an improved flow allows energy and powder consumption to be reduced, leading to significant cost savings. PDF-Download

Pumping paint more gently

Gerd Lübberink

A new range of electric piston pumps reduces resource consumption in paint circulation systems and makes the process more efficient. This leads to lower costs and a longer service life for the pumps. PDF-Download

New gloss finish for cross-border trains

Emil Frei GmbH & Co. KG

Deutsche Bahn (DB) has launched a long-term project to coat articulated railcars with a variety of different coating systems and then inspect them annually. One locomotive has so far had a coating system applied that has produced an impressively uniform finish. PDF-Download

Painting trains more cost-effectively

Lutro Luft- und Trockentechnik GmbH

A new paint shop with a mobile booth and a flexible gate system allows work on different areas of the same train to be carried out in parallel. This reduces throughput times and cuts energy costs. PDF-Download

Joining forces to produce a new painting robot

Dürr Systems AG

Two market leaders collaborated on the development of a new fully automatic painting robot. Together with the robot manufacturer Kuka, Dürr has launched a new ready-to-spray robot specifically for general industrial use. The robot system also meets the requirements of the factory of the future. PDF-Download

A gloss finish in a tough environment

Dr. Carlos Rodriguez Santamarta

For agricultural, construction and earth-moving machines that have to operate in demanding conditions, electrocoats provide a high level of corrosion protection, either as single-coat systems or as primers in two-coat systems. When combined with a top coat, they also offer very good colour and gloss stability. PDF-Download

Paint shop for high-gloss agricultural machines

Eisenmann SE

The agricultural machinery manufacturer Amazonen-Werke has invested in a completely new paint shop as part of a comprehensive programme of modernisation at its production site in Hude-Altmoorhausen near Bremen in Germany. The new paint line offers improved productivity, flexibility and efficiency and a high-quality paint finish. PDF-Download

Single-layer powder coating for furniture

IGP Pulvertechnik AG

By switching from paints to powder coatings, a furniture manufacturer not only made its coating process faster, more reliable, safer for employees and more environmentally friendly, but also introduced more flexibility into the design of its products. PDF-Download

Efficient drying of exterior truck parts

Anton van Steeg

Drying and flashing off water-based paints is a time and energy consuming job to do. The Swedish commercial vehicle manufacturer Scania gives an example of how much a change in the drying process may improve the situation. They retrofitted their Meppel, Netherlands, facility implementing efficient technology at reasonable cost and without extensive rebuilding. PDF-Download

LED units with plug & play technology

Heraeus Noblelight GmbH

A new UV LED system has a plug & play concept for ease of use and micro-optics for the best possible curing results. The LED segments are manufactured in a state-of-the-art production facility with cleanroom technology. PDF-Download

Exhaust air purification that pays off

Robert Klamser

A manufacturer of rubber components and rubber composite components has made a virtue of necessity with its new exhaust air purification system. The system removes the solvent content from the exhaust air and uses it to generate energy in the form of electricity, process cooling and process heating for the company’s base power load. PDF-Download

Cost-effective application of multiple coats

Wolfgang Jungwirth

Applying several coats of paint can lead to a fall in productivity because of the long drying times required. A new system for coating rail vehicles is both more cost-effective and more environmentally friendly than many existing products. PDF-Download