Surface World November 2019 Surface World November 2019 | Page 64

PRODUCTS & PROCESSES
The targets for the new system were
set quite high
4 m tall products with a line speed of
up to 3,5 m/min
Highly efficient powder application
Consistent and uniform 25 microns of
coating thickness
Full automatic coverage of the shelving
corners
Fast color change for flexible production
Clean, environmentally-friendly work place
Once the specifications were defined,
the team started the supplier selection.
“We knew our requirements were
challenging, so we were looking for a
supplier with demonstrated abilities to design
a system to match our needs and reliably
support our production.” Says Lyndon
Clean, environmentally
friendly operating conditions.
Woodfield, Sr. Team Leader, Manufacturing,
who has extensive powder coating
experience with Link 51’s old line.
Link 51 team knew about the positive
experience at their two sister-plants, Lockers
and Pallet Racking, which were using the new
dense-phase powder delivery technology
from Nordson. So, the team headed to
the suburbs of Dusseldorf, to experience the
new spray systems first-hand at the Nordson
demonstration center. “It’s nice to test the
equipment with our products and powder.”
Says Tom Clayton. “Since I was to operate
the new system, having a chance to work
with it without the pressure of running
production was important.”
“A few days of testing at Nordson helped us
gain confidence in the attainability of our
goals. Their solution was easy to work with
and was proven to apply highly controlled
coating thickness
with no operator
intervention.
Process control
was important for
our production
efficiency.” Recalls
Christopher Walker.
“Additionally,
Nordson offered
a special booth
allowing Tom
to clean it from
the top down
using convenient,
high-level openings
with platforms.
That made good
sense to us.”
Because of the
Intuitive controls simplify operator
work and guide colour change.
close team work, demonstrated abilities,
and the special booth solution, Nordson was
awarded the order for Link 51’s new powder
coating system with the target to install in late
December 2018 and start of production on
January 6th – just 3 weeks later.
“Those were intense weeks.” Recalls Lyndon
Woodfield. “In only one week we had to take
out the old system, fill the pit, seal the floor
and have the area ready for Nordson’s
installation team. A large booth with 20
automatic guns had to be ready for
production just 2 weeks later”.
Startup 4 days ahead of schedule
All involved worked like clockwork. From
demolition to installation to startup, Link 51
and Nordson teams worked double-shifts.
On January 2nd, 4 days ahead of schedule,
the first batch of powder coated shelves
came off the line and everyone could breath
a sigh of relief. “A couple of weeks prior to
the start of the installation, our team spent 3
days at Nordson in Germany learning to
work with the equipment. We passed the
learning curve at high speed while at
Nordson. On day one we were ready to hit
the ground running and run full production.”
– remembers Woodfield.
The new system features a custom-
engineered, 6,5 m tall ColorMax ® booth
with a Spectrum ® HD powder feed center
and advanced controls. The booth is
designed to provide reliable powder
containment while also ensuring soft airflow
in the spray area. Special high-level openings
with platforms enable operators to clean the
booth walls from the top down. This way,
no powder is blown in the direction of the
conveyor opening against the booth airflow.
The automatic floor cleaning system keeps
the powder in the booth to an absolute
minimum.
The high line density combines with the
efficient powder application resulting in
minimum overspray. Any airborne powder
is efficiently recycled through a twin-cyclone
system and screened through an ultrasonic
sieve prior to being returned to the fully
enclosed feed center. The new system also
delivers on the fast, contamination-free
colour change. “The step-by-step colour
change instruction on the main controller
and many of the colour change tasks being
fully automated, makes my work much
easier” – confirms Tom Clayton.
The new system operation
Since commissioning of the powder coating
plant, Link 51 team took full ownership of
the process. With the support from the local
Nordson personnel, the applied coating and
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NOVEMBER 2019
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