Nature as a role model

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Pre-programmed for cost-effectiveness

uz

Investing in a new rotary atomiser and a new proportioner allowed Carbo Kohlensäurewerke to improve the cost-effectiveness of its paint shop over the longer term. In addition, the quality of the coatings now significantly exceeds the company’s original requirements. PDF-Download

Generating electricity from waste heat from thermal exhaust air purification

Robert Klamser

JOT has already reported on the benefits of using micro gas turbines for direct electricity generation from the thermal energy of VOC emissions after exhaust air purification. The economic efficiency of direct electricity generation from VOC emissions is reduced for companies with in-house painting facilities and exhaust air flows showing a material composition critical for micro gas turbines. In such cases, it is advisable to generate electricity from waste heat from conventional thermal exhaust air purification systems. PDF-Download

Strategically positioned with “paint shop 5”

Bodo Kleie

A German supplier to the automotive industry has doubled its production capacity with the installation of a new, fully automatic paint shop for bumpers and other vehicle exterior components. The key features of the new paint line are its energy efficiency and reliable operation. PDF-Download

Drying vehicle bodies from the inside

Günter Buzer

A newly developed process allows car bodies to be dried from the inside out. This innovative technology meets all the requirements for the drying processes of the future. The transverse operating mode of the new process, which is in use for the first time, makes it possible to design highly compact systems. PDF-Download

Excellent light conditions for surface inspection

Eisenmann SE

A new LED light tunnel makes the final inspections of painted vehicle bodies much simpler and more efficient. Adjustable light units allow the light emitted to be adapted to the colour of the body. The results are a higher surface quality and lower maintenance, energy and reworking costs. PDF-Download

High-Speed Zinc Flake Coatings

Christian Lenzmann

Zinc flake systems have been an essential part of vehicle manufacturing for several years. The extreme static, dynamic and temperature-related stresses that they are exposed to in the world of motor racing create the ideal test environment and make it possible for the coatings to be further improved. PDF-Download

Powerful pumps for viscous materials

J. Wagner GmbH

The maintenance measures needed in the infrastructure sector and the demand for heavy-duty corrosion protection are constantly increasing. Powerful, reliable application systems and equipment are needed for protective coatings based on extremely viscous high-solids paints. PDF-Download

Offshore repairs in record time

Sika Deutschland GmbH

A solvent-free two-component coating has been developed during the course of a research project, which can be used to repair corrosion protection coatings on offshore wind turbines. The new coating also cures under water in record time and has high levels of impact and abrasion resistance. PDF-Download

Sweden — A pioneer in the field of automation

Gema Switzerland GmbH

Sweden is responsible for any number of innovations which range from Viking longboats, dynamite and ball bearings through to the SLR camera. The Scandinavians also take a progressive approach to powder coating and have introduced modern technologies and high levels of automation into the process. The three examples below demonstrate the intelligent uses of automation in Swedish industry. PDF-Download

A high degree of confidence in the quality

Springer Fachmedien Wiesbaden

In the powder coating sector, fast colour changes, the quality of the end product, the reliability of the application system and the maintenance costs are key factors in ensuring that businesses are lean and profitable. In order to achieve this objective, two British powder coating companies invested in dense phase technology and the latest generation of equipment. PDF-Download

Simply apply two coats

IGP Pulvertechnik AG

Powder coatings that protect steel from corrosion are generally applied in two layers. One way of improving the efficiency of this process is known as powder-on-powder application, which involves omitting the interim curing phase. A manufacturer of metal components has successfully put this process into practice using standard powder coatings. PDF-Download

FEM simulation of loads improves safety

Jürgen Emptmeyer GmbH

For paint shops that need to increase their internal safety levels, the finite element method is a cost-effective alternative for simulating the load capacity of hooks and hangers. This process can be used during the development phase and helps to identify potential cost savings. PDF-Download

Aiming high with a new conveyor system

Frank Berg

Liebherr has invested in a new coating line for its crane components, some of which weigh several tonnes. A heavy-duty power+free conveyor ensures that the parts, which are more than 12 metres high, can be transported smoothly. PDF-Download

Paint strippers — Ready-to-use and reliable

Carsten Zollitsch

Over recent decades, the range of effective chemicals for removing coatings from steel and aluminium in the form of high-quality, ready-to-use products for all types of surfaces has expanded rapidly. As a result, specially formulated paint strippers are now available for specific applications. PDF-Download

Ready for new applications

Gerhard Koblenzer

Enclosed machines are the ideal solution for the ultra-fine cleaning of parts with complex shapes because all types of liquid chemical cleaning and drying processes can be used. In addition, new technologies such as cyclic nucleation and hybrid procedures are available. PDF-Download

New stabiliser systems for highly reliable processes

Safechem Europe GmbH

New stabiliser systems can increase the reliability and cost-effectiveness of parts cleaning processes. Adding the correct dose of stabiliser to the cleaning agent can extend the service life of the machine and the solvent. PDF-Download

Removing machining oil effectively

Doris Schulz

At a car manufacturing company, aluminium crankcases are pre-heated in an oven in preparation for the following process. A customised dry cleaning system using vacuum suction ensures that the parts are clean before being pre-heated. PDF-Download

Carefully managed water system for complex paint pre-treatments

H2O GmbH

A manufacturer of alloy wheels and aluminium rims has invested in two vacuum distillation units which effectively recycle the wastewater from its pre-treatment process and create a sustainable water circulation system. PDF-Download