EISENMANN
Powder Coating
EISENMANN is among the
leading worldwide manufacturers of complete coating
lines. We work with the most
advanced technologies and
experience gained over the
decades from several hundred
real-world paint lines.
EISENMANN is the expert
partner for future-oriented
surface technology in all areas
of industrial coating, from job
coaters to the automobile
industry.
Working in small teams, our
engineers collaborate with
specialists in environmental
engineering, conveyance technology, and control technology
to develop individual system
designs.
We demonstrate our competence in more than just equipment
design. As operators of complete painting facilities for the
auto industry, we are responsible through our own personnel
for economic facility operation
and the highest surface quality.
Contents
Advantages of Powder Coating 1
Powder Coating Lines
from a Single Source
2
Glass Powder Booths
4
Powder Booths with
Filter Recovery
5
Booths with Cyclone
Separation
6
Changing Colors
7
Cleaning and Pretreatment
8
Material Flow Automation
9
Powder Curing Ovens
10
Real-World Examples
11
Service and Maintenance
12
Continuously providing new designs, EISENMANN
is the trend-setter in surface technology.
Example: the glass booth(above) or powder lines
for the automobile industry.
EISENMANN Technology and Know-how:
EISENMANN Powder Coating Systems.
Convincing Advantages
The advantages of powder
coating compared to other
coating processes are convincing:
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>
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Virtually loss-free coating by
means of overspray recovery.
High-quality coating with an
extremely scratch-resistant,
shock-resistant, and
corrosion resistant surface.
No exhaust air problems,
no paint sludge.
>
>
Easy to automate.
Coating thickness of
40 to 200 m (1.5 to 8 mils)
are possible in one coating.
Color Selection no
Problem
Advanced powder booth and
custom system designs make
Over time, companies of all
possible economic operations
sizes and from all fields have
and a high degree of flexibility
made good use of these advant- even for users who change
ages. Now the auto industry colors frequently. EISENMANN
trendsetter in terms of quality, has the right system for every
economy, and environmental
use: powder booth with filter
compatibility - has also joined recovery, cyclone separation,
the ranks of those using
or combined systems for both
powder applications with
methods.
equipment from EISENMANN.
The first ever overhead powder top coat line for the the automobile industry from EISENMANN.
1
Advantages from Custom Solutions:
The Complete Powder Coating Line from a Single Source.
Perfect Fit
Turnkey - all equipment
components in perfect harmony
with each other - that’s your
new powder coating line from
EISENMANN:
Water-saving pretreatment,
powder booth made of glass or
stainless steel, energy-saving
ovens, efficient material flow
systems, and advanced controls. EISENMANN has its own
in-house experts for all of
these areas of concern. So
you only need a single party
to answer all your questions
regarding the implementation
of your new powder line.
Today’s coating lines are integrated
in the production flow, reduce emissions and wastewater. Together with
EISENMANN, this manufacturer of
mailbox systems in the photograph
on the left has implemented state-of
the art coating facilities at various
locations.
EISENMANN delivers automatic and manuallyoperated powder booths for all application systems..
2
In order to obtain first-class surface
quality, the workpieces must undergo
a perfect pretreatment which is
specifically laid out for your parts.
Fancy controls for appliances
(above): All process parameters
can be displayed and altered on the
viewing screen on the control panel.
Diagnostics can be conducted in the
same manner.
Flexible material flow systems,
like EISENMANN’s Power & Free
Conveyor, organize the production
flow and connect the coating
process to the production processes
both upstream and downstream.
3
Transparent in Every Respect:
Powder Booths Made of Glass.
Transparent in every respect:
EISENMANN has created powder
booths made of glass. Special
safety glass and walk-on
stain-less type steel floors
have proven their value in
real-world operations.
The Advantages
of Glass Booths
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>
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Less powder adhesion than
in conventional booths
because the booth walls
cannot be electrostatically
charged.
Super-smooth surface, very
good for cleaning.
The ideal workspace for the
manual coater. The transparent booth is easy to see
into and permits personnel
to have visual contact with
the work environment.
Because of the well balanced
electrostatic conditions, the
powder cloud goes directly
onto the workpiece (instead
of onto the coater).
Clean Floor,
Best Surface Quality
Best coating quality is
achieved when there is little
powder in circulation.
This is why an automatic floor
sweeping system is integrated
into EISENMANN powder
booths; it conveys overspray
powder, that has not reached
the recovery system, into the
reservoir.
This is how the floor sweeping
system, in conjunction with
the powder recovery system,
forwards all of the overspray
immediately back into the
powder circulation system.
4
Clean Air without Losing Powder:
Powder Recovery with Filter Systems.
Powder booths with filter
recovery have proven themselves in the most strenuous
real-world conditions.
The Advantages
Plastic Filter:
Highest degree of separation,
high mechanical stability,
easy to clean.
Powder booth, recovery, and
Better Air Flow:
filters form a unit in which
Horizontal powder cloud with
the complete recovery system
better wrap-around.
can be exchanged depending
on the color desired. The filter Short Powder Paths:
is cleaned automatically during Reservoir is directly below
ongoing operations, the exhaust the filter!
Rapid Color Change:
air is returned directly to the
Detachable recovery units,
hall as circulating air.
movable powder booths or
automatic filter cleaning
system.
Easy Operation:
All units requiring maintenance
are accessible and controllable
during operation (i.e., sieve
This manufacturer of radiators uses
machines, reservoirs, etc.).
the glass booth with performance
Conveyor
Powder booth
made of glass or
stainless steel
Housing unit
with filter
blow-off unit
Reciprocator
with guns
Powder filter
made of
sintered plastic
Inspection
hatch
Powder
sieve
Refill
opening
EISENMANN
Powder reservoir
Fluidized bed
plastic filter..
5
For Many Colors and Small Series:
Powder Recovery with Cyclone Separation.
Conveyor
Powder booth made
of glass or stainless
steel
movable
multiple
cyclone
Reciprocator
with guns
to
absolute
filter
Powder booths with cyclone
separation (mono- and multiplecyclones) are ideal for distinct
many-color coaters. In general,
the cleaning of the separator
system in cyclone booths is
simpler than in filter booths,
although the powder loss is
higher.
The exhaust air travels horizontally through side openings into
the cyclone. The recovered
powder is transferred through
a conveyor and a sieve into the
main reservoir.
EISENMANN
Vibrator for
powder container
Sieve machine
Intermediate powder container
for conveying powder over long
distances for high powder throughput.
6
This manufacturer coats aluminum
profiles and facades in many special
colors in an EISENMANN powder
booth with a mono-cyclone.
From Black to White:
Implementing Colors Changes.
The following criteria are
important in terms of good
color changing concepts:
>
Frequency of color change
and production time per
color.
> Percentile distribution of
colors to be processed.
> Number of colors to be
processed.
> Capacity and utilization
of the system.
When throughput is not very
high and the color is only
changed every few days, a
single additional recovery
unit generally suffices.
Frequently several movable
powder booths are used
when there are high levels
of throughput with standard
colors and additional special
colors.
When a booth is off-line, the
color is changed by exchanging
the complete recovery unit or
by cleaning the filter in the
special automatic cleaning
system. Booths with cyclones
have proved worthwhile for
very frequent color changes
with small production runs.
Diagram below: High rates of
throughput and many colors require
several partial powder lines that
have different recovery systems.
Shown in the diagram: designs
for rapid and economic color
changes with two or more
movable powder booths with
filter recovery systems.
Powder line 1
Standard colors
The right fit in color change
design is a requirement for efficient
operations for job coaters with
frequent color changes. EISENMANN
offers individual solutions with
its movable powder booths and
different recovery systems.
Powder line 2
Standard colors
Powder line 3
Special colors
Booth 1
Booth 2
Filter booth 1
Filter booth 2
Cyclone chamber
7
High Quality and Practical Environmental Protection:
Cleaning and Pretreatment.
EISENMANN’s advanced pretreatment equipment saves
fresh water and wastewater, is
environmentally friendly, and
ensures the greatest surface
quality.
Maintaining and extending the
life of process and rinse baths
is not just economical, but it
also makes environmental
sense.
So today rinse water is used
multiple times using counterflow or recycling techniques.
Life for cleaner baths can be
increased substantially by
dividing into multiple zones
or by using continuous oil
separators.
Further standardized concepts
are available for extending the
service life and are optimally
selected by EISENMANN in
accordance with the application in question.
When the throughput is not all
that high, a wastewater-free
pretreatment utilizing an
evaporator is an interesting
alternative. No water goes to
the drain; any distillate flows
immediately back into the
system.
Spray pretreatment with numerous options for bath maintenance.
Degreasing I
Degreasing II
Schematic of effluent-free pretreatment.
8
Rinsing I
Rinsing II
DI rinsing
Everything in Motion:
Material Flow Automation at the Highest Level.
EISENMANN develops in-house
the complete material flow
and control technology for
automatic coating lines.
We work out the best solution
for you individually in terms
of efficient production flow,
greatest operational reliability,
and highest degree of economy.
Overhead conveyors, Power&
Free conveyors, skid conveyors,
programmed hoist systems, lift
stations, transfer mechanisms
and specifically developed
special conveyors are finetuned to the workpieces and
the operation.
Handling devices or gantry
robots are available for
connecting different conveyor
systems and for workpiece
loading and unloading.
Ideal in coating and painting
operations are destination
controlled, flexible and robust
Power & Free systems.
Gantry robots connect different
conveyor systems in a wheel
coating operation. The robot
transfers the just-powdered wheels
from the spindle conveyor to the
chain-on-edge conveyor of the
powder curing oven.
9
Economical and Energy-Saving:
Powder Ovens, Any Style.
EISENMANN curing ovens are
designed for high efficiency
and the best surface quality.
Continuous ovens with single
or multiple passes or block
arrangements with the water
dry-off oven are heated directly or indirectly with oil, gas,
electricity or recovered energy.
The structures range from
floor-mounted single chamber
ovens to elevated multiple
pass ovens with energy-saving
bottom entry/exit and optimized heating designs.
There are infrared ovens for
workpieces with temperature
sensitive components or high
material thicknesses. Infrared
ovens are also frequently
employed as pregel zones for
conventional convection ovens
because of their excellent
cross-linking effect on powder.
Melting phase with IRM
emitters
Powder oven
Circulating air duct
Circulating air duct
Circulating air duct
Circulating air duct
Circulating air duct
Circulating air duct
Water drier
Combined water drier and powder oven with IRM emitters and air recirculation for aluminum wheels.
10
Four Possibilities, out of a Hundred:
Real-World Examples.
This company offers its customers lighting systems in a great variety of
colors. Using the new EISENMANN powder line, it is economical to process
standard colors in large lot sizes and special colors in small batches.
Heaters are increasingly delivered in fashionable colors. With two automatic
booths for standard colors, 1 automatic booth having 6 recovery units for
special colors, and one manual booth for small production runs and individual pieces, this manufacturer has ensured his competitiveness far into the
future.
The first European plant for EC priming and powder coating of fully welded
truck chassis was planned and built by EISENMANN. After electro-coating,
the workpieces weighing up to 6 tons each are top coated in one of the
three powder coating booths.
Complete powder coating plant with Power&Free system for compressor
housings.
11
Service and Maintenance
The EISENMANN Service offers
an extensive range of services.
These are tailored individually
to the customer's needs, thereby taking the know-how of the
customer's employees, the cost
structure, the processes and
the need for expertise into
consideration.
Therefore, we regard ourselves
as system providers when it
comes to meeting the individual customer's requirements.
Maintenance Management
• Inspection
We determine the actual state
of your system by conducting
inspections and then inform
you about the weak spots and
possibilities for increasing your
performance, or let you know if
there is an urgent need to take
action.
• Servicing
In order to determine the target state of your system, our
specialists not only conduct
the servicing, but also carry
out mechanical and electrical
check-ups and safety tests.
Routine servicing guarantees
an optimum functioning of
your system and increases its
service life.
• Repair
Our maintenance team also
carries out any necessary
repairs and component replacements of course.
• Remote System Diagnosis
Using remote data communication, the remote system diagnosis enables our specialists
to access your controls and
material-flow computers quickly and easily, and remedy any
faults within the shortest time.
12
On-call Service
We offer you a 24/7, on-call
service conducted by our
Service specialists, which is
based on a mutually agreed
response time and customised
to your own specific shift
operation and production
times.
Service Contracts
• Maintenance Contracts
You can rely on EISENMANN
Service. We offer you customised Maintenance Contracts
for your system. You are
reminded in good time of
the next routine service which
is carried out by qualified
engineers. This enables you
to plan the costs on a continuous basis and reduce the
system downtimes by taking
preventative measures.
• Full Service
Due to our excellent experience gained in the construction and operation of highly
automated industrial systems
and factories, we are able to
take over the entire maintenance of your system, allowing
you to fully concentrate on
the key processes of your
business. We guarantee system
availability at all times, and
the value of your systems is
preserved long-term through:
materials handling. We adapt
your systems engineering to
new conditions if, for example,
you should wish to increase
your throughput, or the
product dimensions or weights
have changed, or if your space
planning necessitates this.
We likewise offer you a first
class service where production
relocation is concerned.
• Updates
Modernisation or conversions
to new systems require modification measures, such as
replacing controls, software
and hardware updates, for
example. Our specialists, with
their high level of expertise,
are available at all times.
• Preventative maintenance
• Troubleshooting
• Repairs
Process Optimisation
• System Reconstructions
The EISENMANN Service is your
first contact for system reconstructions or extensions,
whether for paint-spraying and
environmental technology, or
for process technology and
We also offer you advice,
of course, when it comes to
opti-mising your production or
improving it on a continuous
basis. We place application
and process specialists at your
disposal who thoroughly analyse your processes and find
out where the weak spots are.
In close liaison with your
employees targets and measures for optimisation and
plans of action are defined.
Key issues can, for example,
include quality problems, costsaving potential and preventative maintenance concepts.
Run-up Support
With its “standby” concept
EISENMANN offers individual
support on site. Excellently
qualified EISENMANN staff
support your personnel by
accompanying the production
at start-up and also during the
production. Your personnel are
not left to their own devices
here; they have direct access
during the operations to the
“standby” staff who step in
when the situation becomes
critical.
EISENMANN
www.eisenmann.com
EISENMANN Anlagenbau GmbH & Co.KG
Tuebinger Strasse 81
71032 Boeblingen . Germany
Daimlerstrasse 5
71088 Holzgerlingen . Germany
Phone +49 7031 78-0
Fax
+49 7031 78-1000
[email protected]
EISENMANN Service GmbH & Co.KG
Tuebinger Strasse 81
71032 Boeblingen . Germany
Phone +49 7031 78-3000 (6.30 - 18.30 h)
Fax
+49 7031 78-3200
[email protected]
EISENMANN Ingeniería S.A.
Parc de Negocis Mas Blau
Edificio Prima Muntadas
c/Berguedà, 1 . Barcelona
08820 El Prat de Llobregat
Phone +34 93 479-6610
Fax
+34 93 479-6620
[email protected]
EISENMANN France S.a.r.l.
Espace Lumière . 2, Rue Pathé
78406 Chatou Cedex
Phone +33 1 30159800
Fax
+33 1 30531009
[email protected]
EISENMANN Italia S.r.l.
Via Ferrari, 21
21047 Saronno (VA)
Phone +39 02 96718-626
Fax
+39 02 96718-629
[email protected]
EISENMANN U.K. Ltd.
Unit 118 Severn House
Anson Court Business Centre
Staffordshire Technology Park
Beaconside . Stafford
Staffordshire ST18 OGB
Phone +44 1785 283790
Fax
+44 1785 283799
[email protected]
EISENMANN Corporation
150 East Dartmoor Drive
Crystal Lake . Illinois 60014 . USA
Phone +1 815 4554100
Fax
+1 815 4551018
[email protected]
EISENMANN do Brasil
Avenida Duquesa de Goiás, 716
3° andar . Bairro Real Parque
CEP: 05686-002 São Paulo SP
Phone +55 11 21611200
Fax
+55 11 37580030
[email protected]
EISENMANN S.A. DE C.V. Mexico
Blvd. 15 de Mayo 2933
Fracc. Las Hadas
72070 Puebla, Pue.
Phone +52 222 2311712
Fax
+52 222 2498835
[email protected]
EISENMANN Shanghai Co. Ltd.
Room 301, Gubei Intern. Fortune Center
No. 1452, Hong Qiao Road
Changning District
Shanghai 200336 . P.R. China
Phone +86 21 31352188
Fax
+86 21 31352199
[email protected]
OOO EISENMANN
Ul. Pyatnitskaya 47-1
119017 Moscow
Russian Federation
Phone +7 495 951-6824
Fax
+7 495 951-5211
[email protected]
EISENMANN India Pvt. Ltd.
EISENMANN Surface Finishing Systems
India Pvt. Ltd.
Technosoft Knowledge Gateway · 1st Floor
Plot No. B-14 . Road No. 1
Wagle Industrial Estate
Thane (W) 400 604 Maharashtra . India
Phone + 91 22 2583 2929
Fax
+ 91 22 2583 3800
[email protected]