Surface World June 2019 Surface World June 2019 | Page 50
PAINT & POWDER
both via the Nordson PowderPilot HD and
the BSH Wonderware ERP system.
Customer service at Nordson
During start up and commissioning of the
new powder coating line whenever any needs
were identified the Nordson team worked
closely with BSH to offer solutions. The
system could be flexibly and easily fine-tuned
to deliver the desired coating and colour
change performance. “Whenever any area of
optimisation was discovered, the excellent
collaboration and close report by Nordson
personal brought a quick and effective
solution – without interruption to our normal
production.” says Mr. Castillo.”
Second construction phase
and completion
With the objective of being able to coat three
main colours in parallel, two more ColorMax3
booths were installed in 2018. In order to
operate all three booths simultaneously, the
capacity of the conveyor also had to be
increased. A splitter added to the conveyor
system allowed to accelerate the parts
transport and increase production flexibility.
Through smart investment and project
management, BSH fully fulfilled its need for
“any product – any time” production.
The environmental friendliness of the new line
was highly important to BSH. For this, the total
energy and compressed air consumption are not
only monitored and shared between the
Nordson PowderPilot controller and BSH
Wonderware ERP systems, but also minimised
through the implementation of the Nordson
“Going green” performance package. It uses
intelligent controls to adjust the electrical
consumption of the equipment to match the
actual energy requirement at any given moment.
For BSH Electrodomésticos España’s system,
the suspension of product on the chain
conveyor in groups of three with separation
gaps proved optimal to provide a time
window for the automatic cleaning cycle. The
resulting gaps on the line are detected by a
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light barrier and signaled to the control
system, which switches the system
components to standby mode: the spray
systems are switched off, the booth exhaust
system and automated floor cleaning are
switched to stand-by mode, the gun movers
are stopped significantly reducing the energy
and compressed air consumption.
In the startup phase of the installation, the
standby mode would require the minimum of
30 seconds to activate. For further
optimisation this time was reduced to 22
seconds for further energy savings.
The bottom line
“The investment in a new coating line has
paid off in every respect!” Mr. Alzorriz
explains. While discussing the benefits of the
new technology, he starts with the improved
quality. “Our customers offer kitchens in the
upper price segment and the demands their
end customers place today on the surface
finish of a refrigerator are similar to what
they expect of their car. Thanks to dense
phase technology, we are achieving that level
of quality very easily!
Rework due to powder coating operation is
virtually non-existent. That’s one of the most
striking differences from the way things used
to be,” confirms Mr. Castillo: “Our strict
quality controls are met on the first pass
nearly 100% of the time; rework is the rare
exception.” Both believe that the reason for
this lies in high degree of the process control
delivered by the new equipment. “It’s a
complex system of course. First you have to
get your mind around the principles of
operation and their interactions. But then the
system offers a wide range of possibilities for
fine-tuning the individual parameters and
with a little experience you quickly approach
the optimal result” says Mr. Castillo. “We
continuously monitor the energy and
compressed air consumption for example, so
we can optimise them further,” states Mr.
Alzorriz. “The analysis is done with a tool that
provides us with data on the Nordson
PowderPilot HD control system and on our
in-house BSH Wonderware ERP.”
Another positive aspect of the system is, that
energy and powder consumption decreased
significantly even with the gain in production
capacity. “Our biggest savings are in energy
consumption:” reports Mr. Alzorriz, “they are
really dramatic. The fact that we’re
consuming far less energy is not only good
news for us, but also for the entire BSH
Group. We’ve done our part toward
achieving the tremendous savings of 25
million kWh overall between 2015 and
2017! We have accomplished all our goals
and more,” stated Mr. Castillo.
Along with the qualitative progress, the
documented figures already prove a big step
forward. The capacity of the new system is
about four times greater than its predecessor,
and production has already increased as
more parts are being coated. “And that’s
despite the tremendous increase in the range
of products and in the number of colours that
we can now process,” says Mr. Castillo.
“Colour changes are extensively automated
and completed in just minutes. This gives us
the ability to react very flexibly to our
production requirements at all times.”
Information for a box element
Objectives
Increase coating capacity
Flexibility to produce more different parts
Higher surface quality, no rework
Change colours effectively
High degree of automation
Energy savings
High ecological standards
Achievements
Fast, contamination-free colour change
Operating flexibility
Maximum process control for powder
savings and quality
High production rate
Highly automated coating line
Energy savings
Controls integration
Visit: www.nordson.com/ics
Surface World Live 2020 will be returning to Hall 11
at the NEC in Birmingham. The next show will be held
on the 18th & 19th March 2020.
- we have everything covered
JUNE 2019
If you are interested in booking a stand then call Nigel Bean
on 01442 826826 or send him an email at [email protected]
read online: www.surfaceworld.com