Producing Variety Reliably Economical automation in theproduction of powder coating,toner, lacquer and paint

T H E S O L U T I O N

Loading stations for AZO DOSITAINER® and feed hoppers for sacks2

Tapping potentials

Environmental friendliness, creative design opportunities,a variety of hues with a richness of tone, optimum finishes on the most varied subsurfaces: the list ofdemands on paints and lacquers is growing incessantlylonger while the spectrum of raw materials used in production is widening. All these factors are increasingthe demands on plant technology and process control while at the same time offering a huge potential for the optimization of production processes.

The full potential of automation possibilities is far from having been fully exploited in the raw materials feed sector in particular.

In the Right Place at the Right Time

Whether bulk goods, small quantities or liquid components:Combined with innovative process control technology from our processing IT subsidiary hsh-systeme für prozess-IT gmbh,our automatic feeding systemsintroduce all raw materials into the production process at exactlythe right time and in exactly theright quantity. The provision of raw materials is being simplifiedand the supply

of materials from sacks, which isboth labour intensive and criticalfrom the occupational medicinepoint of view, is being reduced. A result of this is a considerableincrease in the precision ofadherence to formula. Intelligentprocess control technology alsopermits reliable and rapid production monitoring. This leads to a clear improvement inthe quality of the end product.

Central material provision: Big bag emptying stations

Producing Variety Reliably

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Efficient Raw MaterialFeed Solutions

Your AZO advantages

• Overall system and processcontrol technology for theproduction of paints and lacquers from one source

• Extensive delivery range:The optimal plant components for each raw material

• High process safety thanksto extensive know-how

• Safe handling even of difficult raw materials

Conveyor scales with dosing screwProcess transparency Fully automatic formula composition with driverless transport vehicles

Solutions by AZO, the technological and quality leader are convincing thanks to:

• Precise adherence to formula,since the closest tolerance limits are complied with

• Optimal product quality as aresult of homogenous blends

• Maximum system availability

• Maximum flexibility with regardto the variety of raw materialsand types as well as the reliabledosing of small quantities

• Innovative conveyor technologyeven for raw materials withextremely difficult removal andconveying characteristics suchas titanium dioxide

• Safe explosion prevention, in particular compliance with ATEX guidelines

• Permanent batchidentification possible

Partially insulated external silos in various diameters and heights

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Powder Coating Production – Economic Automation of Raw Materials in Powder Form

Making use of automation potential

In the field of paint production, considerable automationpotential still exists in the raw materials feeding sector. For receiving and storing raw materials in powderform, AZO is already offering competent solutionsthat have already proved their value in the productionof powder coatings. The automation of titanium dioxidehandling is an example of this. Special silo deliverysystems ensure that reliable silo delivery and stable conveyance are achieved for this particularly fine-grainedraw material with difficult removal and conveying characteristics. The choice of suitable material and the high quality finish make it possible to avoid caking.

AZO Dosing Systems: Precise Weighing in the Loss-In-Weight Process

AZO dosing systems are particularly suitable for formulaswith small components, whichmust be weighed in the mixingcontainer with great precision and which also have difficult flow properties, such as titanium dioxide for instance. The negativeweighing technique makes it possible to ensure dosing andweighing accuracy to the nearestgramme. AZO dosing systems

can be added to at any timethanks to their modular design.The easy-to-clean AZODOS®

devices combined with intelligentprocessing technology enable acomplete change of formula in the shortest possible time.

Safe Batch Separation andFreedom from Contamination

Safe batch separation and freedom from contamination areobtained in interaction with the

Outdoor silos for titanium dioxide and chalk AZODOS® for the accurate provision of small quantities

Operating terminal with touchscreen panel

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Mixing container concept with fully automatic

formula composition

innovative AZO COMPONENTER®

AZO COMPONENTER® hopperreservoirs are filled by pneumaticconveyance from silos or directlyvia big bag loading stations. The various components are transported by the dosing systemand weighed directly in the mixingcontainers, which are driven underthe AZO COMPONENTER® onmobile scales. The special devicesused for discharging and loadingprovides particular conveyanceand transport systems that ensure the safe transport and precise positioning of the mixing

container. At the loading stationthe container is detected using a barcode, automatically collected, filled according to its formula, thendischarged again at the end of the

dosing and weighing process. It is then fed to the mixer or temporarily stored for later processing.

Hopper reservoirs with dosing screws that dose directly into the mixing container as

it moves under the dosing positions

Economic Automation in Powder CoatingProduction.

Your AZO advantages

• Extensive delivery range:Optimal plant componentseven for raw materials with difficult removal andconveying characteristics

• Heat-sensitive resins canalso be stored in outdoorsilos giving greater silo volumes without the needto allocate cost-intensiveinterior production surfaces

• Reliable transport systemsfor the safe movement andpositioning of containers

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Powder Coating Recovery – Reliable Screening and Conveyor Systems

Cost reduction through optimum product utilization

As is the case in many other sectors, powdercoating/covering is exposed to increasing cost pressureand must at the same time fulfil the highest qualitydemands. Efficient powder recovery improves processsafety and is economically decisive. Systems reliably eliminating foreign particles and agglomerates must be used in order to avoid any loss of quality.

In combination with the proven suction conveyorsystems, AZO cyclone screening machines have proved themselves to be outstanding in the recoveryof powder coating. These systems are also the mostsuitable for the recycling of overspray powder.

AZO Cyclone ScreeningMachines: foreign matter andagglomerates are out of luck

As the inventors of cyclone screening technology with decades of experience, we haveopened new dimensions for screening techniques. Our cyclone screening machines combine operationally safe technology with high performanceand easy maintenance and cleaning. The closed system ensures a dust-free working

method. The screening machinescan easily be integrated into exi-sting systems thanks to their com-pact design.

Cyclone screening technique operating principle Cyclone screening machine in easy-to-clean design

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Economic Circuit

The overspray powder that issprayed past the workpieces to be coated falls into a collectingtray where it is collected and fedto the AZO cyclone screening

machine by the suction conveyorsystem. This eliminates agglomerates, lumps and anyimpurities that may have been created during spraying. The filler obtained in this way is fedback to the spraying process.

Optimal ProductUtilization through SafePowder Coating Recovery.

Your AZO advantages

• Fully automatic eliminationof agglomerates andforeign matter

• Particularly efficient working method

• Patented, innovative technology

• Compact, space savingdesign

• Can easily be integratedinto existing systems

• Particularly easy to clean and rapid screen inspection

The overspray powder is collected in the collecting tray, removed by suction and fed back to the cyclone screening machine. After any agglomerates and lumps have been removed there, the powder coating is fed back to the spraying process

Rapid screen inspection

Newly developed cyclone screening machine for powder coating

»The investment pays for itself very quickly thanks to the efficient working method and the savings made in the useof materials. This is a result of optimized powder coatingrecovery made possible by AZO’s innovative cyclone screen-ing technique. It increases your competitiveness markedly!«

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Pneumatic Suction WeighingSystems for Greater Economy

Pneumatic suction weighingsystems are ideally suited to theprecise provision of large andmedium-sized components inpowdered form in the productionof printing colour. The individualcomponents are weighed by conveyor scales and fed to the dissolver via a sluice or dosingscrew. Large components arepneumatically fed directly out ofsilos during this process. Medium-sized components stored in bigbags and containers, such as

special carbon black types, aretransported to the dissolver bypneumatic suction conveyance via big bag loading stations or container emptying stations andthe conveyor scales. The advantages of AZO’s pneumaticsuction weighing systems areclear: the conveyance of many components to one or more dissolvers is done in the mosteconomic way possible.Processing takes place in dust-free, closed systems and the special design of the AZO suction weighing systems saves space and height.

Big bag emptying station with hoist and pneumatic conveyance. In this case there is also the possibility to couple to different lines

AZO suction weighing system for dissolver loading

Printing Colour and Toner – Production in the Closed Process

Precision Technologies for Powder-Fine Raw Materials

The automation of large and medium-sized components,some of which have very low apparent weights such as carbon black, places particularly high demands on plant systems and processing technology. Production in a system that is closed to the greatest possible extent ensures dust-free production processes. The precondition for this is the most extensive automation possible of all raw materials beginning with large, mostly hard components, through to small components such as pigments and additives.

AZO’s proven pneumatic systems are the basis forthis in addition to reliable big bag loading stationsand container emptying stations.

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AZO Containment Solutions forSafe Batch Separation andFreedom from Contamination

Precise dosing of the componentsand exact reproducibility and strictbatch separation are needed in the production of toner. AZO'scontainment systems represent an optimum solution to theserequirements. The individual

components are provided in theAZO COMPONENTER® hopperreservoirs for this purpose. A container travels under the AZO COMPONENTER® and collects the individual elements in accordance with the formula.The number of components is just as variable as the form of the product task.

Economic and SafeProduction of PrintingColour and Toner.

Your AZO advantages

• Extensive delivery range:optimal automation solutions even for difficultraw materials with lowapparent weights and large volumes, such as carbon black

• Clean separation of lineswith positive and negativelyloaded products in the caseof toner production

• High process safety thanksto extensive know-how

Gentle suction conveyor systems for the continuous loading of containers, dissolvers and other devices

Contamination-free formula composition with integration of the mixing process

Collection containers on moveable device with integrated

scale. It is driven under the dosing positions and filled in accordance with the formula

»Dosing systems with collection containers on driverless hanging scales used for highly accurate weighing ensureclean line separation and maximum possible freedom from contamination.”«

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Safe Handling of Fluids

Depending on the task for dosing large components, eithervolumetric flow meters are usedor the fluids are filled directly into the mixing container, whichstands on scales. Medium-sized components are dosed and weighed via scales. Two different systems are usedfor this depending on the fluid.The precise negative weighingtechnique is particularly suited to the task of weighing highly viscous fluid components. The

Versatile Solutions Needed

The extensive and versatile raw materials spectrumwith an abundance of components makes automationsolutions for paint production a special challenge.

The automation of the raw material feed is particularlyimportant in order to relieve operating personnel.Transparency and safety during raw material storage,exact reproducibility of the often-extensive range of products and safe handling of liquid components arerequired in order to achieve this.

Internal silos that transfer raw materials intopneumatic suction weighing systems via introduction systems and dosing systems.

ManDos system for precise, operator-controlled weighing of the smallest quantities

Dissolver feeding with suction weighing systems

Lacquer Production –Exact Reproducibility with Maximum Product Diversity

positive weighing technique isused for fluids that flow easily. The AZO cyclone screening machine has proved itself in the area of safe screening and the elimination of agglomerates in paint production. It excels in particular thanks to itseasy-to-clean and easy-to-serviceconstruction, easy operation andsturdy, high quality design at a reasonable price.

AZO DOSINENTER®, the new dimension of small component automation11

Versatile LacquerProduction Solutions.

Your AZO advantages

• Contamination-free batchcomposition

• Safe handling of very many components, fluids and paints

• Economical Automation of Small Quantities

• Environmentally friendlyproduction

• High flexibility through low cleaning requirementsand simple product changeovers

• Verifiable and reproducibleproduction at all times

• Innovative systems for lacquer production in the continuous process

Small quantity automation with the AZO DOSINENTER® and fully automatic large component feed

Economical Automation ofSmall Components

The AZO DosiBox® is ideal for theautomation of small componentsdelivered in vats, big bags andsacks. The external containers are transferred into the low-costdosing containers in PE plastic at a special loading station. Theyenable automatic access to allsmall components. Identificationsystems make it possible to determine the contents of eachindividual DosiBox®. Closed access via the integrated dosing

homogenization. This saves time, investment and staff. The AZO DOSITAINER® system is an optimal solution for theserequirements. It doses the dry products and delivers them to the continuous processes.Product changeover can be donewith minimal quantities being left over. The AZO DOSITAINER®

has special geometry and a safeintroduction system, making it ideally suited to even the heaviest products.

New Trend: Continuous Lacquer Production

At present a trend towards thecontinuous production of lacqueris emerging. The main advantageof this is the dosed introduction of powders into fluids within closed dosing systems and noenvironmental damage. A furtherbonus is that larger quantities canbe produced with small machinesand low space requirements. A single machine handles severalprocess steps, such as addition,wetting, pre-mixing and

screw is dustproof and decisivelyincreases production safety. The DOSINENTER®- System,which is built in a linear mannerfrom several DosiBoxes, allowstransparent stock control, flexibleformula change and the exactreproducibility of each formula.The ManDos manual weighingsystem provides an outstandingsolution for the smallest quantitiesfor which automation is notworthwhile.ManDos makes the completedocumentation of the smallestquantities possible.

Fluid scales for the precise weighing of the fluids used

DosiBox®

Ideal for the automation of smallcomponents delivered in vats, big bags and sacks. The low-costdosing container in PE plastic with integrated dosing screw permits automatic access to allsmall components.

Product Feeding Systems for Sacks Complete series of filling funnelswith corresponding suction filtersand empty sack compressors forcarrying bulk goods into closedsystems with low levels of dust.

Pneumatic Feeding Systems for DissolversFor the gentle loading of agitatorcontainers. Designed as suction or pressure conveyor systemsdepending on requirements.

AZODOS® Dosing SystemsThe precision dosing systemsfrom AZO work according to the Loss-In-Weight principle and permit the continuous loading of processes, even with low fluidity powders.

Emptying Stations forBig Bags and Containers with AccessoriesModular design optimally suited to your individual requirements.Efficient solutions for all commoncontainer and big bag types, including with sleeve. Perfectlycomplemented by the proven connecting systems from AZO.

Cyclone Screening Machines for Powder CoatingAZO cyclone screening machinescombine operationally safe technology with high performanceand easy maintenance and cleaning. The screening machinescan easily be integrated into exi-sting systems thanks to their compact design.

Tap the full automation potential!In addition to complete solutions for the production ofpaints, lacquers, toner and powder coatings, AZO alsodelivers partial systems as well as machines that open up new rationalization potential for you and increase your competitiveness.

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AZO GmbH + Co. KGD-74706 Osterburken Tel. +49 6291 92-0Fax +49 6291 92-9500info@azo.de, www.azo.de