Surface World September 2019 Surface World September 2019 | Page 49

Intuitive operation Initial results: it was worth it!
The powder coating system is controlled
by a PowderPilot HD control system from
Nordson. An icon-based touch screen user
interface provides the operator with relevant
information about the status of individual
system modules as well as step-by-step
instructions when – during a colour change,
for example – operator intervention is
required. For the most part language-
independent, the control system makes
operation very intuitive and largely eliminates
operator error and training needs. After 30 months of planning and
construction, the project’s first phase
comprising the new production hall
with the powder coating line inside started
up for the first time in November 2018 –
with impressive results from day one.
For individual workpieces and for workpieces
with highly complex geometries that cannot
be coated in the powder coating booth
system, a manual coating booth was
installed. The manual glass booth
supplied by the system integrator Rippert
Anlagentechnik GmbH & Co. KG was
equipped with a Nordson Color-on-demand ®
System, which was supplied by iOS
Industrieofen-Service GmbH together
with their powder management system.
This system is designed for ten colours
and up to 15 colour changes per day.
Minimising environmental
impact and maximising
energy effi ciency
What strikes the eye immediately is the
tremendous improvement in surface quality.
While coating thicknesses with the old
coating system line generally varied between
150 and 200 µ, the use of the new system
was able to lower the coating thickness by
approx. 80 µ down to 120 µ. A high level of
process control, due to Nordson’s Dense-
Phase Technology, will allow the customer
to achieve further powder savings and higher
quality as he can precisely control his powder
application in further optimisations.
Welcome side effect: Over the long term,
the considerably enhanced coating
consistency will be accompanied by major
material savings. For the H.P. Kaysser plant,
the target savings were estimated to be
around 30%. Actual signs of significantly
reduced powder consumption are already
apparent and its exact extent will be closely
monitored and documented.
Another value testifies to the exceptionally
economical and sustainable operation of the
system: although the automatic booth’s 96%
cyclone efficiency requirement represented
an ambitious target, it was achieved already
during the start-up phase.
With their choice of efficient dense phase
technology, highly automated components,
an integrated plant control system with
barcode identification of carriers and,
not least, a 50% increase in production
capacity, the “Surface Finishing” business
at H.P. Kaysser is perfectly prepared for
continued long-term growth.
Timm Kaysser’s interim assessment is
positive. “By all appearances, I’d say that
together with our industrial partners and
tradesmen we’ve put something together
here that works really well.” And with a grin,
he adds: “The best ingredients and not
too many cooks – all of whom agree on
the recipe: As in so many other cases,
this was the key to success here.”
Visit: www.nordson.com/ics
Investment in a new production plant is
inextricably linked with the expectation of
decades-long utilisation. “Decision-makers
of my generation can no longer focus almost
exclusively on technical and commercial
aspects. Today, we also give environmental,
sustainability and energy-related questions
the same priority, right from the start,”
says Timm Kaysser.
Having opted for a fully solvent-free,
eco-friendly powder coating system with
sophisticated cleaning and conveying systems
that essentially eliminate powder waste,
he has no doubt whatsoever that he’s
on the right path to long-term sustainability.
Moreover, the new automatic coating line
is configured for exceptional energy-saving
operation due to the Nordson “Going Green
Package”, whereby devices operate in
combination with an intelligent control
system, to continuously adapt to the actual
energy requirements of the moment.
For example, when the light barriers detect
significant gaps in the supply of products to
the booth, all powder guns are switched to
standby, and the booth airflow is reduced
to the minimum required extraction rate,
using a frequency inverter to reduce the
electrical power required.
For individual workpieces and for workpieces with highly
complex geometries a manual coating booth was installed.
read online: www.surfaceworld.com
SEPTEMBER 2019
47