Pre-treatment System

Application case of automated powder coating line for hardware tools Project Background A hardware tool manufacturing enterprise mainly produces various manual and electric tools such as wrenches, pliers, screwdrivers, etc. For a long time, enterprises have faced problems such as uneven coating thickness, poor adhesion, low production efficiency, and serious environmental pollution by using traditional manual painting or simple dipping processes. With the increasing demand for surface quality in export orders and the tightening of domestic environmental policies, enterprises urgently need to introduce an efficient, environmentally friendly, and adaptable automated powder coating solution for small batch production of multiple varieties. Process flow design Pre treatment: The workpiece enters the spray pre-treatment channel through the suspension chain, and goes through processes such as degreasing, water washing, surface adjustment, phosphating, etc. to remove surface oil stains and oxide layers, forming a dense phosphating film to enhance coating adhesion. Drying: By circulating hot air in the drying channel, the moisture on the surface of the workpiece is completely removed to prevent the formation of bubbles during spraying. Electrostatic spraying: This is the core process. After the workpiece enters the powder spraying room, the automatic reciprocating spray gun group first applies a large area of uniform spraying to the surface of the workpiece. For the complex geometric shapes of hardware tools, such as the inside of the handle of pliers and the opening of the wrench, a manual spray station is equipped to use the principle of electrostatic adsorption to ensure that the powder can penetrate deep into blind spots and achieve all-round coverage. Powder recycling: The bottom of the powder spraying room is connected to a large cyclone recycling system. Unadsorbed powder is sucked in by negative pressure and separated by a cyclone. More than 98% of ultrafine powder is recycled to the powder supply center for reuse, greatly reducing material waste. High temperature curing: After spraying, the workpiece enters the curing oven and is baked at a temperature of 180 ℃ -200 ℃ for 15-25 minutes (depending on the thickness of the workpiece) to melt, level, and solidify the thermosetting powder, forming a hard and wear-resistant protective layer. Cooling offline: After solidification, the workpiece is naturally cooled or cooled by an air cooling section before being manually offline and packaged. Project Results A leap in coating quality: solving common defects in traditional processes. Powder coating has extremely strong wear resistance, corrosion resistance, and impact resistance, especially suitable for hardware tools that are frequently rubbed and used, and has a delicate appearance texture. Production efficiency improvement: Automated assembly line operations have replaced inefficient manual spraying, resulting in a significant increase in daily production and stable production pace, enabling timely delivery of large quantities of orders. Significant cost reduction: high powder utilization rate, and the overspray powder can be recycled, resulting in minimal material waste. Environmental compliance: There are no volatile organic compound emissions during the production process, and the workshop dust is treated by the recycling system to meet the emission standards, fully complying with environmental safety supervision requirements and eliminating environmental hazards for the enterprise. High flexibility: The Great Whirlwind Recycling System reduces the color change time to less than 20 minutes, perfectly adapting to the production characteristics of the hardware tool industry of “multiple varieties, multiple colors, and small batches”. Summary The successful application of this hardware tool powder coating line not only helps enterprises solve the dual problems of environmental protection and quality, but also enhances the brand’s competitiveness in domestic and international markets by improving the appearance grade and durability of products, achieving a win-win situation of economic and social benefits.  

  Automatic powder coating line for yacht manufacturing Project Background With the development of the high-end yacht market, customers have put forward strict requirements for the decoration, weather resistance, and environmental standards of yacht appearance A well-known yacht manufacturing enterprise has decided to upgrade its surface treatment workshop and introduce an automated powder coating production line for small and medium-sized yacht hull and deck structural components in order to replace the traditional high pollution liquid paint process and solve the problem of low efficiency of manual spraying. Process Flow Pre processing stage: Automatic powder coating spraying stage: Powder recovery system: High temperature curing stage: The workpiece enters the immersion treatment tank through a suspended conveyor chain, and undergoes oil removal, rust removal, and phosphating treatment in sequence. Then it enters a hot air circulating oven for thorough drying to ensure that the substrate surface is free of water and oil, providing the best foundation for powder adhesion. This is the core of the production line. Equipped with automatic elevators and reciprocating automatic spray gun units. The system controls the spray gun to perform multi angle and multi-level reciprocating scanning spraying based on preset yacht component contour parameters. Significantly reduced the frequency of manual powder supplementation. Unadsorbed overspray powder is collected through the cyclone recovery device at the bottom and the secondary recovery system of the filter element. After screening, it is sent back to the powder supply center for recycling, achieving high utilization rate of the powder The sprayed yacht components enter the gas heating curing oven. Bake at a constant temperature of 180 ℃ to 200 ℃ for about 20 minutes to melt and level the powder coating, forming a high hardness and high gloss protective coating.   Project Results Significant environmental benefits: It completely solves the problems of exhaust gas and wastewater pollution caused by traditional spray painting, fully complying with national and local environmental regulations. Excellent coating performance: Compared with traditional paints, powder coatings perform excellently in terms of UV resistance, seawater corrosion resistance, and impact resistance, greatly extending the service life of yachts in marine environments Production efficiency improvement: Automated continuous operations have replaced tedious manual operations, shortened production cycles, and made color changing and cleaning convenient and fast, adapting to the production mode of yacht manufacturing with multiple varieties and small batches. Cost savings: High powder utilization rate and no need for primer, significantly reducing material costs. Summary The successful production of the automatic powder coating line for the yacht not only enhances the overall quality and market competitiveness of yacht products, but also provides a replicable benchmark case for the green transformation of the yacht manufacturing industry.

    Application case of semi-automatic powder spraying line for aluminum profiles Project Background A certain aluminum profile processing enterprise mainly produces industrial profiles for building doors and windows. The original manual spray painting process of the enterprise can no longer meet the production needs of high efficiency, environmental protection, and high quality. Therefore, the company has decided to introduce a semi-automatic electrostatic powder coating production line to enhance its surface treatment capabilities. Solution Based on the factory conditions, daily production capacity (about 2-5 tons), and the production characteristics of multiple varieties and small batches, a set of horizontal semi-automatic electrostatic powder spraying lines has been customized for the enterprise. Main process flow · Loading: Manually suspend the workpiece on the conveyor system · Automatic spraying:Two reciprocating automatic spray gun systems with automatic elevators are used to evenly spray according to the profile contour. · Manual spraying:Two workers use manual spray guns for supplementary spraying to ensure no blind spots are covered. · Powder recycling: The powder spraying room is equipped with a recycling system to collect and recycle unadsorbed powder, with a powder utilization rate of over 97%. · High temperature curing:The sprayed profile is manually pushed into the curing oven. Bake at a temperature of 180-200 ℃ for 15-20 minutes to melt, level, and solidify the powder, forming a dense and smooth protective layer. · Cooling unloading:Natural cooling followed by manual unloading and inspection Project Results · Significant efficiency improvement: Compared to traditional manual painting, production efficiency has increased by more than 50% · Excellent coating quality:Electrostatic spraying ensures that the appearance quality of the product meets the industry’s high standards. · Significant cost reduction: The powder has a high utilization rate and can be recycled, reducing raw material waste. · Environmental and safety standards: The powder recycling system effectively controls dust pollution and improves the working environment in the workshop. · Strong flexibility: Especially suitable for the production of multiple varieties and small batches of orders, with convenient and fast color and type changes. Summary The successful application of this semi-automatic powder spraying line significantly enhances the added value and market competitiveness of the product.  

Project Location：China Workpieces Type：Household appliances such as refrigerators and ice makers. Model：Automatic Powder Coating Line. Details：Equipped with spray pre-treatment, automatic powder spraying booth, and bridge type curing furnace.     In order to meet the requirements of Wancheng electrical equipment Company for quality, production capacity, and environment, Colin provided an automated powder coating line in Wancheng electrical equipment Company’s new factory   Based on the demand of Wancheng electrical equipment Company for expanding the production capacity of refrigerators, ice makers and other electrical appliances. This spraying line is equipped with an automatic powder spraying system. Capable of achieving rapid color change and ensuring coating consistency.   The produced workpieces enter the loading area and are placed on the automatic conveyor system. Afterwards, it will be transported to the spray pre-treatment for surface cleaning. Then enter the drying system to ensure that the surface of the workpiece is clean and dry.   After the preprocessing is completed, it enters the fully automatic powder spraying line, which is equipped with an automatic spraying system and a powder collection system to ensure coating consistency and reduce powder waste.   After the powder coating is completed, the workpiece will enter the solidification furnace for powder solidification, and then enter the unloading area for unloading after cooling.   Considering environmental protection and energy consumption, a waste disposal system has been added   The entire system is controlled by a PC, with visualized production for easy monitoring and operation.