plastics painting - eisenmann.us.com · fields of production, painting, assembly or distribution....
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P l a s t i c s P a i n t i n gEISENMANN
EISENMANN designs and constructs plants for surfaceengineering, material flow automation, environmentalengineering, firing lines for ceramics and specializedplants for coating, recycling, heat treatment and energyrecovery.
Approx. 2400 employees worldwide, half of which areengineers or technicians, develop new ideas for thefields of production, painting, assembly or distribution.Among them are experts and specialists with well-founded know how in various areas of expertise and
industry sectors. An advantage that ismirrored in tailored concepts withstate-of-the-art technology and a highdegree of economic efficiency.
Another result of our efficient product-ion and assembly strategies: Our pro-duction centers are tailored to therequirements of individual customers.They facilitate the production of a plantconfiguration especially adapted to yourneeds.
When complex systems are involved, we install the entire plant in our housebefore we deliver it to put the plant to the acid test. Only when the pre-assembled function modules have passed the test run, will they be handedover to the customer.
This method considerably saves timeand cost for assembly and facilitatesinstallation in your house without eveninterrupting the production process.
Of course we will assist you even aftercommissioning, if you want: Our After-sales Service provides for professionalmaintenance, short repair times andimmediate procurement of spare parts.
ContentsPlastics Painting Systems 1
Pretreatment Plants 2
Spray Booths with Disposal Facilities 4
Practical Examples 6
This is EISENMANN
EISENMANN Technology Center in Holzgerlingen
Having delivered more than 250 painting systems forplastic parts, EISENMANN ranges among the leadingsystem supplier of the industry sector. Among theplants delivered are the largest plants in Europe as wellas the smallest plant for golf balls and the first plasticspainting line for a consistent use of environmentally-friendly water-based paint.
First-class surface engineering quality without rejects isa demand placed on every painting system. Prerequisi-tes are cleaning and pretreatment appropriate for thematerial as well as utmost cleanliness in all plant areas.
For this reason, a primary objective is the consistentenforcement of dust-protection measures. Examples areenclosed plants with an optimally adjusted air balance,bottom-mounted conveyor systems, air showers andantistatic treatment of the workpieces with ionized air.
Inside the spray booths, the paint mists are dischargedsystematically through a vertical air conducting system.Plastics painting lines are planned individually depen-ding on the types of workpiece, throughput rates and
material characteristics. Our customers paint glass-fiberreinforced polyester parts, colored or crystal-clear thermoplastics as well as foamed PUR parts. Examplesare passenger car attachment parts such as bumpers,exterior mirrors or lenses, mounting parts for the interior of passenger cars, TV and VCR housings, mobilephones, sports equipment, phone booths and manyother pieces of equipment.
All the pretreatment, application, drying and materialflow plant components are exactly designed for the different temperature sensitivities and deformation characteristics of the respective workpieces.
EISENMANN offers target-oriented material flow systemswith state-of-the-art control systems, automatic hand-ling and user-friendly visualization systems especiallyadapted to the special conditions of plastics painting.
To reduce emissions and disposal cost for exhaust airand waste water, we plan all the processes involvedwith integrated environmental engineering systemsright from the start.
Highest quality can only beachieved with utmost clean-liness, extensive supervisionand inspection, and perfectsystems engineering.
Robots have gained acceptance in almost all fields of plastics painting. Even with small lot sizes and varying workpiece shapes they are used more and more.
Always on the job: EISENMANN environmentalengineering purifies exhaustair and waste water.
1
Plastics Painting Systems
To achieve optimum adhesion of the paint to theplastic, workpiece-specific cleaning and pretreat-ment is required. Since EISENMANN offers all theprocedures, the optimum variant can be recommen-ded impartially in each case.
Cleaning Using Wet Chemical Methods
Parts with a normal degree of soiling are cleanedthrough alkaline spray degreasing and then rinsedwith DI water. This enhances the paint adhesion andremoves tenside and salt residues that would affectthe quality.
More heavily soiled parts are degreased in two stages at higher temperatures and using higherspray pressures. If integrated separating agentsmust be removed, acidic cleaning agents are used.The workpieces are degreased and rinsed in twocycles, then rinsed again with DI water.
Workpieces made of polyolefins are additionally submitted to a surface treatment consisting of aflame treatment, fluoridation or plasma treatment.
EISENMANN is implementing the first plasma plantin "online" mode for an automobile manufacturer.The quality enhancement: Without any manual inter-vention and without touching the surfaces, theworkpieces on their skids are transferred from the wet chemical cleaning system via the plasma treatment to the painting booth.
Pretreatment Plants
EISENMANN
Sectional view of a pretreatment plant
Tunnel completelyin stainless steel
Zone 1Degreasing
1.5 barheated
Zone 2Rinsing 11.2 bar
Zone 3Rinsing 21.2 bar
Zone 4DI rinsing1.0 bar DI water
FilterHeatexchanger
Was
tew
ater
Adjustable nozzles
Spraying collar
Tunnel insulation
Skid conveyor
Inspection hatch
Screen
Basin insulation
Stainlesssteel basin
Multi-stage cleaning plant (acidic cleaning agent) with water-saving cascaded track
Pretreatment and cleaning plant with skid conveyor
2
3
Pretreatment plant with circular conveyor for reflectors of vehicle lamps
For effective removal of water residues, blowing zones are installed at the exit of the pretreatment plant.
If desired by the customer, an additional tilting and joggling zone can be installed for workpieces that tend to scoop matters(see fig. below).
EISENMANN designs and constructs maintenance-friendlylarge-capacity spray boothsmade of stainless steel andglass for manual painting orpainting by robots. They areoptionally equipped with anintegrated sludge removal unitthrough floor scrapers or with a central water trap.
The most effective separatorsystem is the cross flow currentdouble venturi scrubber, thenozzle shape of which providesfor an especially effective removal of the paint mists from the exhaust air.
The downstream relief zonesprovide for an extremely effecti-ve separation of solids attainingvalues below those specified inthe TA-Luft.
To save expenses for fresh waterand waste water, the water inthe scrubber is circulated. Coagulated paint particles arecontinuously removed in exter-nal sludge removal systems.
Especially for plastics paintingsystems, EISENMANN has deve-loped tailored solutions withsurface scrapers or decanters assludge removal systems.
When using water-based paints,the possibility of implementingthe economical and environmen-tally friendly water-based paintrecycling system via ultrafiltra-tion should be taken into consideration.
4
Painting vehicle attachment parts in China
Spray Booths with Disposal Facilities
Large-capacity spraybooth with cross flowcurrent venturi scrubberand partial flow removalvia a decanters
Circulating spraybooth water
Compressed paint sludge
Decanter
Circulating water trap
Water recirculation in the partial flow
Paint shop for exterior vehicle mirror housings
5
Spray booths in clean room technology with air showers
Paint line for vehicle attachment parts with skid conveyor system
Plastics painting line for bumpers
6
Job Coating Systems
This automobile supplier has already received the 4thEISENMANN plastics painting line for his broad scope of products ranging from large spoilers to small vehicleattachment parts. A comprehensive skid conveyor systemis used for transport..
Practical Examples
Primer
Base coat
Clear coat
Pre-treatment
LoadingUnloading
7
Automobile Suppliers
Plastic parts for special series automobilesare a specialty of this South German auto-mobile supplier. The complex paint line withrobot application and skid conveyor systemthey are using is just as flexible.
8
Automobile Manufacturer
This Russian automobile manufac-turer relies on EISENMANN quality:
Bumpers and various plasticattachment parts are perfectlypainted on two parallel large-
capacity paint shops.
The paint shops are designed for a production of 800,000
vehicles/year.
Practical Examples
Pre-treatment
Blowing zone
Regenerative
thermal oxidation
RTO
Wastewater
Loading / Unloading
Base coat
Primer
Clear coat
MaskingWater drier
Clear coat drier
Primer drier
Plastics instead of Glass
High-transmission plastic parts areused instead of glass componentsmore and more. These require sophi-sticated scratch-resistant coatingunder clean room conditions.
Depending on the geometric data ofthe parts, the workpieces are eitherflooded or spray coated using robots.
Photo left: Panorama roofs are flowcoated on an EISENMANN line toachieve a first-class, scratch-proofand UV-resistant layer.
Photo above: Coating line for the application of scratch proof paint on headlamp lenses, with automatic handling by robots.
Photo above left: Flow coating line for headlamp lenses.
Photo left: Spray coat line with robot for headlamp lenses.
Coating of Polycarbonat
Digi
· J
uly
2005
www.eisenmann.com
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