Surface World September 2019 Surface World September 2019 | Page 47

PAINT & POWDER
The right recipe for
sustainability and growth
H.P. Kaysser is growing
and planning for the future.
Their new powder coating
plant provides the flexibility
to economically coat small
and large workpieces in
series production or batch
size one.
H.P. Kaysser GmbH + Co. KG in
Nellmersbach, Germany is one of the
leading companies in the area of sheet
metal machining and processing. In order
to raise the technical and performance
capabilities of their surface finishing facilities,
H.P. Kaysser invested in a new powder
coating system, using dense phase technology
with state-of-the-art application engineering
from Nordson.
With more than 70 years of experience
providing development and strategy support
to customers from practically every business
sector, today H.P. Kaysser offers intelligent,
economical solutions that range from
engineering services and the full sheet metal
processing chain right through to logistics.
With some 30,000 m² of facilities, the
company’s fully automated operations
fabricate and process products made of
steel, cast iron, stainless steel and non-
ferrous metals – as individual units or
in small, medium or large batch sizes.
Customers take advantage of their high
quality, low prices and rapid lead time, with
the company experiencing steady growth.
H.P. Kaysser have always excelled in surface
finishing and even in their early history they
focused on alternatives to liquid coating
systems. When H.P. Kaysser installed their
first powder coating plant in 1969, this new
technology had only just been launched on
the market, and their plant was one of the
first and biggest in Germany. The vintage
system was still fully functional and in
daily service until recently, working
alongside a second unit, installed in 1989
to automatically process larger workpieces.
Over the past 30 years, coating operations
and associated processes such as colour
change and system cleaning have achieved
Booth, powder guns and powder feed center form an integrated colour change system that enable eight
extensively automated, extremely rapid and contamination-free colour changes. Nordson HDLV pumps are
virtually maintenance-free, which means they also enhance quality, fl exibility and production benefi ts
over the long term.
such a high level of automation that modern
powder coating lines are essential when
it comes to meeting the demands of
“smart factory”: maximum flexibility for
the economical production of even small
and extremely small series right down to
“batch size 1”!
Sustaining growth,
enhancing flexibility
The modernisation and improvement of
powder coating capabilities to meet current
and future requirements were nothing new
to Thomas Kaysser, CEO of H.P. Kaysser
and son of the company’s founder. He had
already been focusing efforts in this area
for some time when, in the spring of 2015,
he asked his son Timm to be responsible for
the planning and construction of a new
coating system. “We were looking for the
right combination of the highest quality
coating, in an optimal process,” recalls
Timm Kaysser. “Firstly, we needed the best
ingredients for the identification and coding
of workpieces throughout the transport,
pretreatment, masking and coating
operations. But we also needed an intelligent
control system to link everything together.”
Accordingly, the plant specifications stated
the following requirements:
Secure investment in long-term,
future-proof technology
Extremely high flexibility in production
Minimised environmental impact
and maximised sustainability
Creation of capacity to coat all in-house
production in the company’s own coating
system, irrespective of the size and weight
of the components.
Creation of additional capacity to cover
subcontract work as a job coater.
The size of the components to be coated
and the resulting dimensional requirements
for the powder coating system soon made
it clear that this project would require
significant investment and the construction
of two brand new production halls.
For the planning and configuration of the
coating technology, Kaysser drew on the
extensive experience of CS Oberflächentechnik,
a company that had already participated in the
creation of several major powder coating lines.
CONTINUED ON PAGE 46
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SEPTEMBER 2019
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