In-House Coating Line with Maximum Process Control

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For more than 60 years, the Spanish company Giménez Ganga has been producing sun protection systems and distributes around 60,000m2 of it’s products in more than 70 countries every year. Until 2018, the powder coating has been sent to an external job coater. "We used to pack and unpack and then transport to and from the factory – that was very time-consuming, cost-intensive and not very flexible," says Juan Giménez. "So we thought about what a complete coating line of our own would look like." From a technical point of view, the size and shape of the parts had to be considered first. Added to this was the variety of materials; besides aluminum, iron and zinc alloys are also processed. Lastly, all solutions had to be designed to meet the high demands for quality, process reliability and environmental friendliness.

Precise powder application and significant powder savings

Finally, in January 2019, the installation of a new complete powder coating system took place. The system was designed to accommodate the parts, which are up to 7 m in length. The parts had to first undergo a chemical pre-treatment. One tank is available for each the multi-metallic alkali and the alkaline treatments of aluminum, which comprises of seven stages. The prepared parts are then fed through a state-of-the-art Nordson powder coating system consisting of a coating booth (ColorMax3), 12 automatic powder guns (Encore HD), complemented by the powder feed center (Spectrum HD) with advanced control system (PowderPilot HD), Nordson twin cyclone and after filter. The spraying system uses HDLV (HighDensity powder, Low-Velocity air) dense-phase technology to pump more powder through the spray gun with a minimum amount of air, and maximum process control. This results in superior efficiency, unmatched coverage, and reliable self-clean color change, boosting productivity and reducing operating costs. The extremely robust and durable pumps have zero wear parts affecting the powder output. The soft powder cloud delivers uniformity and efficient coverage even at high output. The fast color change booth, the powder guns and the powder feed center together form a powerful colour change system that makes production at Giménez Ganga more flexible and even makes the coating of small batches more economical.

The complete article was published in IST 03/2021.

Author(s): Nordson Deutschland GmbH, Erkrath (Germany); Giménez Ganga, Polígono Industrial El Castillo, Sax-Alicante (Spain)

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