- Email: [email protected]
Benefits from the change to powder bell atomiser
F O C U S resulting product is as stable as that produced using conventional technology with a small grain size distribution, suitable for use in thin coatings and films. There is increasing use of non-solvent powder coatings in the US, Europe and, particularly, Asia, in response to the need for environmentally friendly coatings. Japan Chemical Week, 20 Nov 2003, 44 (2246), 2
INSTALLATIONS Major new MDF powder line in Holland Ecocoat BV, located in Breda, Holland is a new company established for the coating of MDF board. In 2001 the owner contacted Eurotec Finishing Systems to investigate the potential for applying powder to MDF as a cost effective alternative to multiple coats of wet paint or the application of vinyls and other laminates, with the added benefit of being an environmentally friendly coating system. During 2002 a number of tests were carried out to evaluate the suitability of the powder system. It was appreciated that there was a need to use high quality boards manufactured to tight quality control standards, with an even density profile, which helps to overcome the cracking problems that are sometimes associated with this process. The moisture problems need to be carefully controlled, as this is vital to the successful application of the powder. If humidity is too low the powder does not apply to the work piece, and high moisture content can cause blistering and bubbling in the coating finish as water escapes during the heating process. Powder application and recovery needs special attention since MDF does not possess the conductivity of metal substrates. A final consideration is the need for the operator to have a greater understanding of the process and DECEMBER 2003
O N
POWDER
be able to make changes when substrate conditions alter. Close control and monitoring of process parameters and the subsequent recording of results is vital if high quality results are to be achieved on a continuing basis. At the end of 2002, when all tests and trial runs were completed, paying particular attention to the setting of the gas catalytic curing system employed by Eurotec, the order was placed, and the installation of the plant was completed during the summer of this year. The conveyorised system comprises two gas catalysed infrared ovens, one for preconditioning the board to improve conductivity, allowing the electrostatically charged powder to adhere to the substrate prior to curing, which is again carried out in a plc controlled gas catalytic infrared oven. Application of the powder is achieved using eight Eurotec ‘AG300’ automatic powder guns mounted on two 2m stroke electromechanical reciprocators. Over-sprayed powder can either be collected manually or automatically and sieved prior to returning to the fluid bed hopper and hence back to the guns. Virgin or new powder is also automatically topped up in the fluid bed, controlled by the Eurotec ‘ARTU’ system. The whole system is controlled from a central plc with a touchscreen operator interface using easily followed instructions in colour. The plc is also linked via a modem to Eurotec in the UK for live fault finding, and software modifications and updates. The plant has now started production and is being run as a family business. Surface World, Oct 2003, 16,17
Benefits from the change to powder bell atomiser Powder wastage, poor aesthetics and the inability to apply sufficient powder to maximise productivity were the driving forces behind Italian company Otefal’s recent
C OAT I N G S change to a new ‘SRV 038’ rotary powder bell atomiser from Sames UK. Otefal, a leading manufacturer of coated steel coil, had been using standard, automatic powder spray guns. However, their poor performance was not only resulting in an irregular build-up of the powder coating but also impeding productivity improvements. In house trials proved the Sames SRV 038 to be equal to the task and an order for eight systems soon followed. The operating principle of the SRV 038 powder bell is very similar to that of a liquid paint bell which easily meets the very high transfer efficiency of 85% or more, demanded by the automotive sector. Powder is supplied to the air operated SRV by a standard powder pump. To atomise the powder, an air operated disc/bell cup mounted on an air bearing rotates at high speed, creating a cloud of powder up to 450 mm in diameter. The SRV 038 is said to be ideal for use with flat bed spraying machines and for the coating of products such as white goods, car bodies, floor tiles, glass, steel tubes, fabrications, and MDF board. Its high voltage electrostatic operation combines with a shroud of air to shape the width of the resultant fan pattern. This is adjustable from 250 mm to 450 mm by regulating air pressure to the bell. The feathered edge of each fan pattern naturally overlaps to optimise surface finish. The metal bell cup, which is in fact flat in design, acts as the electrode ensuring the bell cup receives its maximum electrostatic charge. At Otefal, all these factors guarantee its 1.5 m wide steel coil, travelling at a line speed of 18 m/min, receives an efficient coating of powder. Gloss levels and distinctness of image (DOI) are said to be significantly superior. The rotational axle speed of the bell is a major contributor to the SRV’s performance as it ensures the powder particles are 7
F O C US
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POWDER
highly charged. An integrated counter electrode or free ion collector also plays its part by eliminating the risk of an orange peel finish. To meet increased productivity, reliability of the Sames system was an important purchasing criterion for Otefal. The investment has also resulted in lower maintenance costs, as only eight SRV bells are required to do the job of sixteen automatic powder spray guns at greater speed. Furthermore, the company has subsequently confirmed it has cut its powder consumption by 20%.
and surfaces will be held in Orlando, Florida, 26-28 January 2004. There are 36 papers covering a wide range of hygienic topics: including antimicrobial technologies, biocides, powder coatings, and many other surface modification techniques.
Surface World, Oct 2003, 24
The 31st Annual Water-borne, High Solids and Powder Coatings Symposium will be held February 18-20 at the New Orleans Marriott. Sponsored by the University of Southern Mississippi, School of Polymers and High Performance Materials, the symposium is a presentation of papers written by industrial,
EVENTS Hygienic Coatings & Surfaces The second global congress dedicated to hygienic coatings
Registration forms available from Janet Saraty, Conference Secretary, Paint Research Association, 8 Waldegrave Road, Teddington, Middlesex, TW11 8EP, UK. Tel: +44 208614 4811. Fax: +44 20 8614 4812. E-mail: [email protected]
The Annual International Waterborne, High Solids, and Powder Coatings Symposium
Focus on Powder Coatings (ISSN 1364-5439) is published monthly by Elsevier Advanced Technology, The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK. 2003 annual subscription rate: US$798/€713/¥94,700, additional copies to the same address US$266/€238/¥31,600. Orders and enquiries International Sales Department, Elsevier Advanced Technology, The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK. Tel: +44 (0) 1865 843687. Fax: +44 (0) 1865 843971. E-mail: [email protected] For US orders Elsevier Journals Customer Service, 6277 Sea Harbor Drive, Orlando, FL 32887-4800, USA. US Customers Tel: +1 (877) 839 7126. Fax: +1 (407) 363 1354. Customers outside US Tel: +1 (407) 345 4020. Fax: +1 (407) 363 1354 Other Locations Elsevier Science Customer Support Department, PO Box 211, 1000 AE Amsterdam, The Netherlands. Tel: +31 20 3853757. Fax: +31 20 4853432. E-mail: [email protected] © 2003 Elsevier Science Ltd. All rights reserved.
C OAT I N G S academic and government scientists that relate to new and emerging technologies. The symposium will include several papers that focus on topics related to powder coatings including: “Diethylmalonate-blocked Isocyanurates as Crosslinkers for Low Temperature Cure Powder Coatings” by Thomas Faecke of Bayer. “Low Temperature Cure (120°C) Durable, Corrosion Protection Powder Coatings for Temperature Sensitive Substrates” by Glen Merfeld of GE. “Improving the Spray Properties of Dry-Blended Pearlescent Pigments in Powder” by Thomas Chirayil of Engelhard. “Acid/Epoxy Reaction Catalyst Screening for Low Temperature Cure (120°C) Powder Coatings” by Glen Merfeld of GE. For registration or more information contact Rick Durden at: Tel: +1 601 266 4475. Fax: +1 601 266 6265, or E-mail: [email protected]
Permissions may be sought directly from Elsevier Science Rights & Permissions Department, PO Box 800, Oxford OX5 1DX, UK. Tel: +44 (0) 1865 843830. Fax: +44 (0) 1865 853333. E-mail: [email protected]. You may also contact Rights & Permissions directly through Elsevier’s home page (http://www.elsevier.nl), selecting first ‘Customer Support’, then ‘General Information’, then ‘Permissions Query Form’. Derivative Works Subscribers may reproduce tables of contents or prepare lists of articles including abstracts for internal circulation within their institutions. Permission of the publisher is required for resale or distribution outside the institution. Permission of the publisher is required for all other derivative works, including compilations and translations. Electronic Storage or Usage Permission of the publisher is required to store or use electronically any material contained in this journal, including any article or part of an article. Contact the publisher at the address indicated. Except as outlined above, no part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior written permission of the publisher. Notice No responsibility is assumed by the Publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Typeset by Land & Unwin, Bugbrooke Printed by Mayfield Press (Oxford)
INSTALLATIONS Major new MDF powder line in Holland Ecocoat BV, located in Breda, Holland is a new company established for the coating of MDF board. In 2001 the owner contacted Eurotec Finishing Systems to investigate the potential for applying powder to MDF as a cost effective alternative to multiple coats of wet paint or the application of vinyls and other laminates, with the added benefit of being an environmentally friendly coating system. During 2002 a number of tests were carried out to evaluate the suitability of the powder system. It was appreciated that there was a need to use high quality boards manufactured to tight quality control standards, with an even density profile, which helps to overcome the cracking problems that are sometimes associated with this process. The moisture problems need to be carefully controlled, as this is vital to the successful application of the powder. If humidity is too low the powder does not apply to the work piece, and high moisture content can cause blistering and bubbling in the coating finish as water escapes during the heating process. Powder application and recovery needs special attention since MDF does not possess the conductivity of metal substrates. A final consideration is the need for the operator to have a greater understanding of the process and DECEMBER 2003
O N
POWDER
be able to make changes when substrate conditions alter. Close control and monitoring of process parameters and the subsequent recording of results is vital if high quality results are to be achieved on a continuing basis. At the end of 2002, when all tests and trial runs were completed, paying particular attention to the setting of the gas catalytic curing system employed by Eurotec, the order was placed, and the installation of the plant was completed during the summer of this year. The conveyorised system comprises two gas catalysed infrared ovens, one for preconditioning the board to improve conductivity, allowing the electrostatically charged powder to adhere to the substrate prior to curing, which is again carried out in a plc controlled gas catalytic infrared oven. Application of the powder is achieved using eight Eurotec ‘AG300’ automatic powder guns mounted on two 2m stroke electromechanical reciprocators. Over-sprayed powder can either be collected manually or automatically and sieved prior to returning to the fluid bed hopper and hence back to the guns. Virgin or new powder is also automatically topped up in the fluid bed, controlled by the Eurotec ‘ARTU’ system. The whole system is controlled from a central plc with a touchscreen operator interface using easily followed instructions in colour. The plc is also linked via a modem to Eurotec in the UK for live fault finding, and software modifications and updates. The plant has now started production and is being run as a family business. Surface World, Oct 2003, 16,17
Benefits from the change to powder bell atomiser Powder wastage, poor aesthetics and the inability to apply sufficient powder to maximise productivity were the driving forces behind Italian company Otefal’s recent
C OAT I N G S change to a new ‘SRV 038’ rotary powder bell atomiser from Sames UK. Otefal, a leading manufacturer of coated steel coil, had been using standard, automatic powder spray guns. However, their poor performance was not only resulting in an irregular build-up of the powder coating but also impeding productivity improvements. In house trials proved the Sames SRV 038 to be equal to the task and an order for eight systems soon followed. The operating principle of the SRV 038 powder bell is very similar to that of a liquid paint bell which easily meets the very high transfer efficiency of 85% or more, demanded by the automotive sector. Powder is supplied to the air operated SRV by a standard powder pump. To atomise the powder, an air operated disc/bell cup mounted on an air bearing rotates at high speed, creating a cloud of powder up to 450 mm in diameter. The SRV 038 is said to be ideal for use with flat bed spraying machines and for the coating of products such as white goods, car bodies, floor tiles, glass, steel tubes, fabrications, and MDF board. Its high voltage electrostatic operation combines with a shroud of air to shape the width of the resultant fan pattern. This is adjustable from 250 mm to 450 mm by regulating air pressure to the bell. The feathered edge of each fan pattern naturally overlaps to optimise surface finish. The metal bell cup, which is in fact flat in design, acts as the electrode ensuring the bell cup receives its maximum electrostatic charge. At Otefal, all these factors guarantee its 1.5 m wide steel coil, travelling at a line speed of 18 m/min, receives an efficient coating of powder. Gloss levels and distinctness of image (DOI) are said to be significantly superior. The rotational axle speed of the bell is a major contributor to the SRV’s performance as it ensures the powder particles are 7
F O C US
O N
POWDER
highly charged. An integrated counter electrode or free ion collector also plays its part by eliminating the risk of an orange peel finish. To meet increased productivity, reliability of the Sames system was an important purchasing criterion for Otefal. The investment has also resulted in lower maintenance costs, as only eight SRV bells are required to do the job of sixteen automatic powder spray guns at greater speed. Furthermore, the company has subsequently confirmed it has cut its powder consumption by 20%.
and surfaces will be held in Orlando, Florida, 26-28 January 2004. There are 36 papers covering a wide range of hygienic topics: including antimicrobial technologies, biocides, powder coatings, and many other surface modification techniques.
Surface World, Oct 2003, 24
The 31st Annual Water-borne, High Solids and Powder Coatings Symposium will be held February 18-20 at the New Orleans Marriott. Sponsored by the University of Southern Mississippi, School of Polymers and High Performance Materials, the symposium is a presentation of papers written by industrial,
EVENTS Hygienic Coatings & Surfaces The second global congress dedicated to hygienic coatings
Registration forms available from Janet Saraty, Conference Secretary, Paint Research Association, 8 Waldegrave Road, Teddington, Middlesex, TW11 8EP, UK. Tel: +44 208614 4811. Fax: +44 20 8614 4812. E-mail: [email protected]
The Annual International Waterborne, High Solids, and Powder Coatings Symposium
Focus on Powder Coatings (ISSN 1364-5439) is published monthly by Elsevier Advanced Technology, The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK. 2003 annual subscription rate: US$798/€713/¥94,700, additional copies to the same address US$266/€238/¥31,600. Orders and enquiries International Sales Department, Elsevier Advanced Technology, The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK. Tel: +44 (0) 1865 843687. Fax: +44 (0) 1865 843971. E-mail: [email protected] For US orders Elsevier Journals Customer Service, 6277 Sea Harbor Drive, Orlando, FL 32887-4800, USA. US Customers Tel: +1 (877) 839 7126. Fax: +1 (407) 363 1354. Customers outside US Tel: +1 (407) 345 4020. Fax: +1 (407) 363 1354 Other Locations Elsevier Science Customer Support Department, PO Box 211, 1000 AE Amsterdam, The Netherlands. Tel: +31 20 3853757. Fax: +31 20 4853432. E-mail: [email protected] © 2003 Elsevier Science Ltd. All rights reserved.
C OAT I N G S academic and government scientists that relate to new and emerging technologies. The symposium will include several papers that focus on topics related to powder coatings including: “Diethylmalonate-blocked Isocyanurates as Crosslinkers for Low Temperature Cure Powder Coatings” by Thomas Faecke of Bayer. “Low Temperature Cure (120°C) Durable, Corrosion Protection Powder Coatings for Temperature Sensitive Substrates” by Glen Merfeld of GE. “Improving the Spray Properties of Dry-Blended Pearlescent Pigments in Powder” by Thomas Chirayil of Engelhard. “Acid/Epoxy Reaction Catalyst Screening for Low Temperature Cure (120°C) Powder Coatings” by Glen Merfeld of GE. For registration or more information contact Rick Durden at: Tel: +1 601 266 4475. Fax: +1 601 266 6265, or E-mail: [email protected]
Permissions may be sought directly from Elsevier Science Rights & Permissions Department, PO Box 800, Oxford OX5 1DX, UK. Tel: +44 (0) 1865 843830. Fax: +44 (0) 1865 853333. E-mail: [email protected]. You may also contact Rights & Permissions directly through Elsevier’s home page (http://www.elsevier.nl), selecting first ‘Customer Support’, then ‘General Information’, then ‘Permissions Query Form’. Derivative Works Subscribers may reproduce tables of contents or prepare lists of articles including abstracts for internal circulation within their institutions. Permission of the publisher is required for resale or distribution outside the institution. Permission of the publisher is required for all other derivative works, including compilations and translations. Electronic Storage or Usage Permission of the publisher is required to store or use electronically any material contained in this journal, including any article or part of an article. Contact the publisher at the address indicated. Except as outlined above, no part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior written permission of the publisher. Notice No responsibility is assumed by the Publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Typeset by Land & Unwin, Bugbrooke Printed by Mayfield Press (Oxford)