IR systems speed powder coating

Edited by the Engineeringtalk editorial team Jul 5, 2007

Two medium-wave IR systems were installed in a very small footprint at a manufacturer of chainsaw blades' new Fujian factory.

By installing infra-red systems, a Chinese manufacturer of chainsaw blades has been able to increase its rate of powder coating, while significantly improving product quality.

The new systems, from Heraeus Noblelight also allowed significant cost savings by permitting better use of available space and cutting energy bills, compared with alternative drying and curing solutions.

China is the world's fastest growing economy and Chinese companies are continually looking for competitive edge for their products in world markets.

When a manufacturer of chainsaw blades moved into a new Fujian factory, it was decided that the powder coating of the blades should be carried out in the most cost-efficient and effective way possible, as this is a very competitive market with enormous downward pressures on prices.

After tests were carried out on the blades at Heraeus' Applications Centre in Shanghai, it was decided that electric infra-red systems offered the best solution.

As a result, two medium-wave systems were installed in a very small footprint.

One of the systems dries the blades as they emerge from a washing treatment, while the other is fitted after the powder coating plant and cures the powder at around 200C.

Both systems feature zonal control to save power when smaller parts are being coated.

In addition, the power output can be easily adjusted to cater for various coating colours, as dark coating requires less energy than lighter coatings.

Since installation, it has been found that there has also been a significant improvement in quality, as infra-red promotes rapid melting of the powder so that there is unwanted run down.

As the company's engineering and maintenance manager reports, "We have not had a single complaint since the new line started operation".

Speed of curing has also been a benefit of the new curing system, as line speed has now been increased by more than 50% compared with a convection oven.

This has been accompanied by a decreased energy costs, as the company was able to take advantage of off-peak electricity rates and the fact that electric infra-red is targeted heat, so that there is no heat waste in heating up the surrounding area.

Heraeus Noblelight offers the complete range of infra-red radiation systems from NIR to medium-wave carbon infra-red (CIR).

It has over 40 years experience in infra-red technology and offers the expertise, products and systems to provide efficient and effective solutions to drying, heating and curing problems throughout industry.

It operates Applications Centres in five countries around the world, with one at Neston, on the Wirral, which serves the UK.

All centres are equipped to carry out proving trials with customers' own materials and can advise on the selection of the optimum emitter to suit particular processes.