Improving Performance and Cutting Wastage

Cost-Cutting Overspray Filtration System

Eike Ostendorf-Servissoglou

A metal construction company has installed a new filtration system for overspray in its paint shop where large and complex components are painted by hand. The compact dry filter system has a low energy consumption and a long filter service life. PDF-Download

Flexible Solution

Peter Kalkenings

A high-performance solution was required at short notice to protect the surface of high-strength lockbolts for use in the automotive industry, which most importantly had to have a low curing temperature. A zinc flake coating met these and other requirements and provided a black top coat to give the necessary high-quality finish. PDF-Download

Clean in Only 20 Seconds

Springer Fachmedien Wiesbaden

A new rapid cleaning device can be used to clean paint spray guns between spraying processes or during colour changes in the space of only 20 seconds. It has been specially designed to be installed outside the spray booth. PDF-Download

Guidelines for Measuring Colours

Reinhard Feld

Colour measurement is an essential part of the production of high quality materials and coatings in the automotive industry. This article gives a number of useful hints on how to get it right. PDF-Download

The Benefits of Paint Recirculation Systems Combined with Pressure Tanks

Springer Fachmedien Wiesbaden

Recirculation systems are often used to supply spray guns with paint and are essential for materials with a tendency to form sediments. If important factors include handling the materials with care, producing first-class finishes and, at the same time, saving energy, systems with pressure tanks are the ideal alternative to those that use only pumps. PDF-Download

Inverted Power & Free System

Doris Schulz

A new power & free conveyor for liquid painting and powder coating lines combines the benefits of power & free overhead systems with those of floor-mounted circular conveyors, multi-track spindle conveyors and skid conveyors. PDF-Download

Partial Shot Blasting of Cylinder Heads

Doris Schulz

Two oscillating chamber shot blasting systems incorporated into the existing production lines of a car manufacturer in southern Germany allow cylinder heads to be partially shot blasted. PDF-Download

High Scratch Resistance for Plastic Parts

Dr. Mathias Mühleisen

The process of applying PVD coatings to substrates in combination with UV-curing paint is growing in importance. This article describes practical applications of the process and explains the high level of functionality of the coating systems with the help of examples. PDF-Download

Extremely Efficient and Robust

Springer Fachmedien Wiesbaden

A new high-frequency generator combines an efficiency rate of 80% with a high level of reliability to give significant cost savings. PDF-Download

A Wider Variety of Finishes and Designs

Rainer Venz

Electroplated coatings provide a high level of protection against wear, thus extending the service life of components. By carefully combining different coatings, it is possible to add further properties, such as colour or increased corrosion resistance. PDF-Download

HFE Precision Cleaning Takes On a New Dimension

Springer Fachmedien Wiesbaden

After a total of four years of planning and construction, Europe’s largest HFE precision cleaning machine was handed over to its operator in November 2012. A shortage of space on the operator’s premises presented a particular challenge during the implementation process. PDF-Download

Please Touch

Inès A. Melamies

The painted plastic switches on a dashboard are touched thousands of times during the life of a car. To ensure paint adhesion on millions of switches and control keys, one of the globally leading manufacturers treats the plastic parts with atmospheric pressure plasma. PDF-Download

Perchloroethylene Instead of Aqueous Cleaning

Markus Mitschele

A well-known manufacturer of bolt-on engine components planned to replace its solvent cleaning machine with an aqueous system. After carrying out numerous tests with several different machine suppliers, the company opted instead for a new solvent system. This article explains why. PDF-Download

Reducing Cleaning Costs by More than Two Thirds

Doris Schulz

The cleaning systems used on modern engine and gearbox production lines in the automotive industry have the highest specific energy consumption of all the machines on the line. This is a very good reason for considering a more efficient approach to cleaning. PDF-Download

Is NMP Still Needed in Coating Removers?

Dr. Jürgen Silberzahn

For many years, NMP was the most important solvent in coating removers that were used primarily to strip aluminium parts. Now, the changeover to products which do not contain NMP has largely been completed and has even been accompanied by an improvement in the results of the coating removal process. PDF-Download

High-Quality Finish with Ultra-Thin Coatings

Springer Fachmedien Wiesbaden

Ultra-thin powder coatings are used among other things to reduce powder consumption. The example of the bicycle manufacturer Derby Cycle illustrates the benefits of this type of system. The quality of the finish on the company’s bicycle frames has improved significantly since the changeover to ultra-thin powder coatings. PDF-Download

Powder Output More Consistent and Controlled

Springer Fachmedien Wiesbaden

The automotive industry requires high standards of quality and punctual deliveries. In order to meet these requirements, a Czech manufacturer of heat exchangers and condensers decided to install a new application system, which enabled the quality of the coatings to be improved without reducing the thermal performance of the components. PDF-Download

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Painting Cars More Efficiently

Dr. Michael Schlipf

As much as 70 % of the energy needed to manufacture a car is used in the painting process. If energy savings of more than 75 % can be achieved in this area, the result is not only a huge drop in production costs, but also a reduction in CO emissions. The paint shop at Volkswagen’s plant in Bratislava has demonstrated that this is possible. PDF-Download