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 LIVE 2020 48 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