Reducing Costs by More Than 50 Percent

Moving from Water-Based Paint to Powder

Heiko Schlindwein

For 20 years, a manufacturer of automated storage and material flow systems coated its products using recyclable water-based paint. Then, the company decided to move to powder coating on the basis of the results of a comparative study. The new machine with separate single-colour and multiple-colour systems has reduced material consumption by 50 percent. PDF-Download

Powder Coating for High-Quality Fire Protection Products

Ewald Gattermayr MBA

Fire protection facilities in buildings are required to meet extremely high standards. The powder coatings applied to products made by an Austrian manufacturer of fire protection solutions not only comply with strict safety requirements but are also aesthetically pleasing in architectural terms. PDF-Download

Footprint 40 Percent Smaller

Eisenmann Anlagenbau GmbH & Co. KG

At its site in the Japanese city of Fujisawa, Isuzu Motors Limited produces commercial vehicles and components. Over recent months, a new paint shop was constructed at the plant while production continued. An E-Shuttle system is responsible for ensuring that 50 truck cabs are transported without problems through the pre-treatment and electrocoating systems every hour. This is the first time that this conveyor system has been installed in Japan, a market which has traditionally been dominated by Japanese suppliers. PDF-Download

Rapid conversion from wet to dry

Michael Eder

Through a temporary and simple paint mist separation facility in existing paint shops, a future professional conversion from wet to dry absorption and its achievable cost savings are easily determined. PDF-Download

Cleaning and Degreasing in Euro Folding Pallet Cages

Markus Mitschele

In the metalworking industry, components are often transported, stored and also cleaned in folding pallet cages. A modular system has been designed for pallet cages of this kind that ranges from a rapid degreasing unit to a three-tank immersion system for precision cleaning. PDF-Download

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Continuous Measurement of the Concentration and Degree of Contamination

Rebecca Dettloffs

In cleaning, rinsing, coating or treatment baths, inline measurement of the bath concentration is essential in order to ensure product quality and to minimise the consumption of resources. Robert Bosch GmbH has therefore equipped the cleaning baths at two of its production plants with a measuring system for continuous bath monitoring. PDF-Download

Is Chrome Needed by the Surface Technology Industry?

Tobias Distler

Despite the fact that there are now many corrosion protection systems on the market that contain no chrome, many coating companies still have reservations about pre-treatment products that are chrome-free. A newly developed range of products based on non-toxic trivalent chrome offers a high level of corrosion protection and avoids some of the disadvantages of alternative systems. PDF-Download

The Path Towards a Successful Technology Transfer

Oliver Penz

German industrial firms are increasingly moving well-established production processes to plants in China and South East Asia. This technology transfer also involves cleaning systems. PDF-Download

Flexible Pre-Treatment System for Agricultural and Construction Machinery

Dr. Thomas Vortmüller

Agricultural and construction machines have to withstand tough conditions and must function effectively over long periods. Alongside a high-quality surface finish, the cost-effectiveness and flexibility of the pre-treatment system are playing an increasingly important role. New phosphate-free systems that can be used with a variety of metals meet all these market requirements. PDF-Download

Dimensionally Stable Anodes used in Hard Chrome Plating

Thomas Ebert

In the hard chrome plating process, dimensionally stable anodes offer several advantages in comparison to conventional systems, such as lead anodes. Their significantly lower energy consumption, shorter downtimes and reduced disposal costs have a major impact in the long term. PDF-Download

Efficient System for Painting Plastic Add-On Parts

Dr. Frank Rothbarth

A new technology has been developed to allow plastic vehicle parts to be coated at low temperatures. It enables a clearcoat to be applied to bumpers, mirror housings and spoilers using an energy-efficient and cost-effective process at a temperature of only 80°C. According to the raw material supplier, in the medium term the new technology will make it possible for car parts made from plastics, composites and metals to be painted together for the first time. PDF-Download

A Focus on Tension

André Fackiner

Technical springs require highly effective corrosion protection. A high-performance zinc flake coating meets these requirements almost off-the-shelf. The main benefits of the system, in addition to its long-term resistance to corrosion, include a smooth finish even on parts with complex shapes, low curing temperatures and the avoidance of stress corrosion cracking caused by hydrogen. PDF-Download

The Right Spare and Wear Parts Automatically in Stock

Peter Spang

A flexible, automated system makes production-critical materials permanently available by automatically issuing repeat orders. A detailed logging function ensures that stock levels are always accurate. PDF-Download

Reproducible electrostatic painting in lab-scale

Dr. Felix Brinckmann

Lab-scaled paint shops are established in coating manufacturing and OEM business to perform reproducible painting tests close to production line conditions. A new LabPainter series was designed to offer more control functions and an improved operation concept. PDF-Download

Four Guns to Cover All Eventualities

Ralf Högel

Robots with four wrist-mounted paint guns are rarely used in practice. However, it was only this complex technical concept combined with innovative system technology that made possible a highly flexible solution for coating a variety of rubber profiles for the automotive industry. PDF-Download

Closed Loop Control of the Coating Thickness in Powder Coating Plants

Alexander Buchmüller

A new measurement and control system allows for full quality control of powder coating thicknesses before curing. In the most advanced version of the system, the booth control unit adjusts the quantity of powder automatically on the basis of the measurements until the coating reaches the required thickness. This avoids the need for safety margins commonly applied to the powder quantity settings in practice and, therefore, reduces powder consumption. PDF-Download

Corrosion Protection for Low-Loaders Applied in Large, Energy-Saving Booths

Ralf Dürr-Krouzilek

The three new large painting booths installed by Ziertheimer Industrie & Lack GmbH have immediately increased the company’s production capacity by 50 percent. At the same time, the diagonal airflow and efficient heating system in the booths have reduced its electricity and gas consumption by 60 percent. PDF-Download

Aqueous Cleaning of Precision Components

Thomas Gutmann

The ongoing reduction in the size of industrial components has led to higher quality standards for the cleanliness of parts and for the entire cleaning process. The introduction of innovative technologies has allowed aqueous parts cleaning processes to meet these high standards and also to offer benefits with regard to particle-free degreasing. PDF-Download