LUTRO Luft- und Trockentechnik. Principles for planning of paint shops 2011

Transcription

1 LUTRO Luft- und Trockentechnik Principles for planning of paint shops 2011

2 COMPANY PROFILE... 4 History... 4 Product ranges... 4 SETTING UP PAINTING DEPARTMENTS... 5 Approval... 5 Planning... 6 Dimensioning... 6 Conception and arrangement... 7 Basis Layouts... 8 Technology and basic costs Connection and operating costs EQUIPMENT FEATURES CONCEPTS FOR REDUCING THE ENERGY/POWER COSTS Automatic flash-off function Energy saving/economy operation Frequency control of the ventilators Heat recovery systems REFERENCE ANNEX FOR CAR PAINTS: LUTRO KSP Technical Data Dimension sheet KSP 7-BT (lateral view of air handling machine) LUTRO Luft- und Trockentechnik GmbH Page 2 from 50

3 IMAGE AND REFERENCE DOCUMENTATION Reference customers from A - Z (extract) Preparation bays / peripheral equipment Painting and drying plants for cars Painting and drying plants for commercial vehicles Image references of commercial vehicles Painting and drying plants for industrial products REFERENCES TO USEFUL LITERATURE DISCLAIMER LUTRO Luft- und Trockentechnik GmbH Page 3 from 50

4 Company profile History Established in 1954 in Stuttgart, today LUTRO Luft- und Trockentechnik GmbH is one of the leading manufacturers of high-quality painting plants. World-wide LUTRO painting plants have been treating surfaces of vehicles and industrial products made from metal, wood and plastic with latest technology. The consistent quest for technical improvement results in a plant quality, whose enormous reliability is proven anew every day for our customers in more than hundred countries. Product ranges Painting plants for painting the cars and commercial vehicles Special painting plants for automobile industry / CKD painting plants Painting plants for training centers (e.g. in the paint industry) and training Painting plants for local passenger transport, streetcars/trams, bus production and maintenance Painting plants for the vehicle production plant Commercial vehicles Special superstructures Buses Rail vehicles Construction Site Equipment. Coating plants for airplane construction Painting plants for the industrial surface technology, especially in the area of mechanical engineering, wind turbines (rotor, drive, live ring and tower painting) and for other plant components Large-capacity painting booths with and without crane flaps. Materials handling equipment for supporting the coating process Phosphating plants and water treatment systems connected to it 2011 LUTRO Luft- und Trockentechnik GmbH Page 4 from 50

5 Setting up painting departments Modern customer service includes maintenance, inspection, air handling machine and accident repair, latter subdivided into sheet metal and paint. In the endeavour to offer this complete service under one roof, more and more companies are confronted with the necessity of setting up painting department. Brief instructions are given below about usefulness and conception of painting departments: Approval Generally the plant supplier should provide you with documents and support for the approval of your plant. Noise development of a painting booth (approx. details for the approval) 2011 LUTRO Luft- und Trockentechnik GmbH Page 5 from 50

6 Planning If it is expected that after covering all personnel, material and operating costs, usual interest on the capital investment and the risk remuneration, a higher return of investment can be obtained than before while allocating painting jobs to external workshops, whereby the in-house expenses for workshop and office expenditures (carting off and picking up of vehicles, bookings etc.) should be taken into consideration. MAKE OR BUY decision: The average, adjusted net annual turnover with external workshops can be regarded here as standard. According to our experiences in medium scale companies this should be at least approx. EUR 100,000/-. Consequently a minimum gross turnover of approx. EUR 150,000/- is necessary in addition to usual surcharges and the attempted increase in turnover while setting up in-house paint shop (statements/details correspond to empirically established figures of our customers and no liability is assumed by us!). Necessary circumstances or strategic decisions can also justify in-house painting departments in case of low turnovers, however so-called One-Man paint shops always remain problematic due to absence of personnel during vacation, illness etc. Dimensioning Unfortunately, the dimensioning of the paint shops is estimated too small in many cases. Right in this area there are quite concrete clues and minimum requirements, depending on the turnover to be expected, the paint shop capacity and the number of the appointed personnel. Following must be included in space requirement: Traffic routes, preparation bays, buffer bays, finishing bays (unless completed in the workshop), paint shop, mixing room, paint depot, machine room, tool room, material room. Especially the topic of efficient process organisation and with it automatically also the topic of traffic routes and intra-logistics is taken strongly into account in the last years. Optimally the total number of the necessary preparation bays should be approx. 50% of the daily objects, besides at least two preparation bays should be available per painter and/or helper LUTRO Luft- und Trockentechnik GmbH Page 6 from 50

7 Size and scope of the paint plants are also determined by the objects to be expected (averages based on experience): Objects Plant type Preparation / lifting platform 5 7 Combi-booths 4/ Combi-booths with sep. dryer 6/ Combi-booths with integrated dryer 10/ Combi-booths with 2 integrated dryers 13/ 8 Two combined painting and drying booths with integrated double dryer Conception and arrangement Basically, similar planning principles as in the workshop planning / equipment apply while planning painting areas: Avoid unproductive areas (e. g. traffic areas) and reduce necessary shunting operations! Nowadays ergonomic requirements of operation such as e.g. climate, cleanliness and lighting round off this requirement profile and always support the efficiency of a paint shop in each case LUTRO Luft- und Trockentechnik GmbH Page 7 from 50

8 Hence following applies as classically ideal-typical arrangement for a paint shop: Runway in the centre, to the left and the right of it the work places; each place technically so perfectly equipped that the vehicle must not be moved up to the painting process in the booth. Combined painting and drying booth with lateral moving equipment for the finishing bay Basis Layouts Subsequently arranged planning sketches show exemplary optimized outlines for new buildings/reconstructions of paint shop. We shall gladly provide you with numerous alternative layouts depending on your requirement and upon request. Paint shop for approx. 5-7 objects per day 1. Combined colour spraying and drying booths 3. Air handling machine room 4. Paint depot with colour mixing room 5. Tool depot Preparation bays / peripheral equipment 2011 LUTRO Luft- und Trockentechnik GmbH Page 8 from 50

9 2011 LUTRO Luft- und Trockentechnik GmbH Page 9 from 50

10 Paint shop for approx objects per day 1. Combined colour spraying and drying booths 2. Dryer 3. Air handling machine room 4. Paint depot with colour mixing room 5. Tool depot Preparation bays / peripheral equipment Paint shop for approx objects per day 1. Combined colour spraying and drying booths (top coat) 2. Dryer 3. Combined colour spraying and drying booths (Filler) 4. Air handling machine room 5. Paint depot with colour mixing room 6. Compressor room 7. Tool / device depot/storage Preparation bays / peripheral equipment Paint shop for approx objects per day 1. Combined colour spraying and drying booths (Filler) 2. Air handling machine room 3. Paint depot (filler) 4. Combined colour spraying and drying booths (top coat) 5. Dryer for 2 vehicles 6. Air handling machine room 7. Paint depot with colour mixing room 8. Tool / device depot/storage 9. Compressor room Finishing bays Preparation bays Preparation bays are approx x 3.50 m large. Suitable devices e.g. central grinding dust extraction and ventilators must be provided for the extraction of dry grinding dust and paint mist/sludge (during filling works on small scale), 2011 LUTRO Luft- und Trockentechnik GmbH Page 10 from 50

11 Owing to further work place optimization, the use of short-lift lifting platforms on the preparation bays will be obvious in the future, because the predominant part of the accident damages is below the "waistline", therefore requires stooped or kneeling posture of the painter. Preparation bays Painting plants for cars and small transporters have following standard useful areas: 1. Combibox 4.00 x 7.00 x 2.90 m (W x L x H) 2. Dryer 3.00 x 7.00 x 2.50 m (W x L x H) 3. Machine room 2.50 x 7.00 x 3.60 m (W x L x H) 2011 LUTRO Luft- und Trockentechnik GmbH Page 11 from 50

12 Paint booth with 4-wing drive through and large glazing Technology and basic costs Spraying causes paint mist/sludge, which must not reach the breathing area of the painter for health reasons. Extractors must therefore be provided for all spraying operations. In principle top-coat is processed in closed booths, because only these rooms can be technically designed such that the extraction of the paint mist/sludge is without any problems and the supply of the fresh air is dust free. In addition, it must be possible to heat the supply temperature constantly at approx. 22 C. The dryer must be directly connected to similarly dust free air circulation and constant temperatures between 60 and 80 C. Both pla nts are regarded as dustfree areas and should be treated and maintained with corresponding diligence. The predominant part of the spray booths delivered by LUTRO is produced today as combi-booths, i.e. the same room can be used for spraying and subsequently for drying. The capacity of these plants can be increased by adding a dryer, which usually sits laterally beside it and is loaded in the cross-transport (Table, Sec. 2). The ventilation must always take place vertically in case of car-booths, otherwise satisfactory painting result is not achieved. Most of the booth floor should be gridded completely because then deposited dust falls below the gridded floor and cannot be whirled up again. The usual heating agents are gas or oil, also hot water or steam can be used if necessary. Present favourite is natural gas, the cleanest fuel and mostly available as directly fuelled system without transmission losses. In case of high vehicle throughputs and the use of water-based paints, additional ventilation systems can also reduce the drying period. However precaution should be taken while selecting suitable systems, since the use is always also connected to organizationally modified operating processes and a majority of systems presently available in the market entail increased risk of additional swirling of dust. The time saved in the painting process is so often faced with additional expenditures in the finishing process! Please consult the experts about the use of these technologies in this respect! The costs fluctuate according to technical equipment of the plants and the preparation bays. They amount e.g. for a preparation location with exhaust to approx. EUR 15,000/-, for a combi-booth approx. EUR 60,000/- and for a combibooth with laterally connected dryer approx. EUR 90,000/- respectively plus value added tax [vat] (non-binding planned values, prices of LUTRO Luft- und Trockentechnik GmbH Page 12 from 50

13 Additional options such as e.g. Heat Recovery Plants, Direct Heating with Gas or Frequency Converter clearly lower the heat energy consumption (modern heat recovery systems have such exemplary recovery factors almost up to 50%). In this case especially, also ensure maintenance-optimized version of these systems and the combination with bypass ducts for the summer operation. Depending on efficiency the additional costs for heat recovery systems in the repair painting are between approx. EUR 6,000/- to EUR 12,000/- plus VAT, according to the experience the amortization stretches over a period of approx. 1-2 years and depends on the operating mode and use of the plant. Frequency converters offer the option of educing voltage peaks and consequently of possibly being classified into more favourable power tariffs. In addition, the air in the booth can be optimised as required. In this way different operating modes such as full load (paint shop), partial load stages (preparation operation / spot repair) and Stand-By operation can be defined. The costs of such systems are between approx. EUR 6,000/- and EUR 12,000/- depending on motor output of the booth and version/execution. Connection and operating costs Sufficient connection outputs must be provided for power and heater. Approx. 3.5 kw should be provided per preparation bay for extraction, compressed air, tool and lighting. The combi-booth requires approx. 18 kw power and 242 kw heating capacity (with heat recovery plant approx. 186 kw, combi-booth with dryer approx. 25 kw power and 370 kw heating capacity (with heat recovery plant of approx. 250 kw). The compressor for the compressed air generation should be designed adequately, at least approx. 500 l/min. effective output in case of two employees, approx. 100 l/min per person should be additionally provided in case of higher number of staff. In case of the compressed air supply, please ensure particularly the use of energy efficient supply systems and inlets; the saving effect against the old systems still installed in several companies is however quite amazing! The operating costs of painting plants are between 10/- and 15/- per hour (average empirically established figures of our customers) for power, heater, maintenance and wearing parts such as e.g. filters, whereby it should be determined that plants with separated dryer are more economical than pure combi-booths, since heating up can be omitted after each spraying process, and the heat loss could be reduced further by using optimized insulation materials LUTRO Luft- und Trockentechnik GmbH Page 13 from 50

14 Equipment features LUTRO painting plants are designed according to the latest state of the art technology and individually coordinated to the requirements of our customers. In this case all plants meet the relevant DIN / EN standards and can generally be used for conventional as well as water-based paint systems. An overview of essential equipment features of our plants is summarized below: Booth enclosure The enclosures of our plants are always made of special high-quality, zinc-plated sheet steel components with white (RAL 9010) coating on both sides and with an intermediate insulation. Filter ceiling The large-area filter ceiling with weight compensation used successfully for years is patented world-wide by LUTRO. Leak tightness and comfortable operation during the filter change are the most important advantages of this successful own development and are already proven in countless plants world-wide. Booth lighting Special, 4-flame energy-saving lamps are integrated in the booth ceiling and side wall with a pitch of 30 /45. This arrangement ensu res a very good combination of large-area filter ceiling, uniform laminar air flow and ideal lighting, which can largely avoid shadows. Side wall lights can also be used for taller booths. Paint separators The paint separation is effected by means of elastic high-efficiency separation mats which hold the paint deep inside. They are installed below the level of the grid. Apart from this, the conceptual routing of the air flow of our plants allows a uniformly accelerated routing of the air flow in the area of the object surface. This leads to a most intensive extraction, an optimal separation and an increased paint absorbing capacity of the filter. These are highlights for the efficiency of your investment! Air handling machinery Especially aerodynamic, electrolytically zinc-plated and top-coated metal enclosures house reliable and energy-saving heavy-duty air handling machinery and is equipped with inspection openings with quick-locking system. Heating equipment The heating equipment is equipped with a 4-traction system for optimum efficiency. The combustion chamber of the air heater is designed according to the 2011 LUTRO Luft- und Trockentechnik GmbH Page 14 from 50

15 high temperature stress in heavy-duty heat resistant stainless steel. The air supply unit including air heater and burner are DIN-DVGW tested units. The exhaust air pipeline of the plant ends with a deflector hood in approx. 10 m over the upper edge of the floor. The realized blow out/exhaustion speed is min 7 m/sec. And thus corresponds to the current official editions according to VDI Alternatively, direct heating systems are used more and more frequently for gas heated systems. Our employees in the project department can give you more information about the preferences of this heating equipment (no loss of power, incremental power division, flue gas pipes are not required,..). Control and regulating system Our plants are usually equipped with a state-of-the-art programmable logic controller (PLC). All operational and functional processes can be selected and executed by means of a clearly arranged control panel. Functions are shown by way of on-screen text displays which are easy to understand. By simply pushing a button, additional information about the current operation can be retrieved (spaying - drying, temperature, time, booth pressure, condition of the filter etc.). In case of malfunctions, the info button can retrieve the cause and also correction recommendation. An exact cost monitoring is possible by means of operating hours counter, service life of the ventilators, burners etc. Operating errors can be reduced and an effective, economical and environment protecting work can be ensured in this way. Over an additionally available diagnostic interface, operating data can be exchanged online with our technical centre; malfunctions can be detected and usually corrected. In addition following operating variants are integrated series-equipped in our PLC for the reduction of the power consumption (economy circuit) and for the optimized processing of water-based paints (automatic flash-off): Economy circuit A press switch activates the economy circuit the plant is operated or shut down for an adjustable period. Automatic flash-off function The booth can be automatically switched to automatic flash-off function for the acceleration of the flashing-off process. Time and temperature can be set according to the specific requirements of the used paint system Processing of water-based paint systems For years the state of the art technology is certainly using the water- based paint systems. In this respect, LUTRO painting plants are naturally designed for the use 2011 LUTRO Luft- und Trockentechnik GmbH Page 15 from 50

16 of these paint systems. For high throughputs in paint centres, LUTRO Quick-Dry is providing a highly reliable state-of-the-art technology, which we would like to discuss in details. Processing of UV paints All LUTRO paint booths are basically suitable for processing conventional and water-based paint systems. LUTRO provides dryers as option taking into consideration the use of UV-paints and objectively and neutrally discusses the usage purpose as well as chances and risks of the use of UV-paints known at present LUTRO Luft- und Trockentechnik GmbH Page 16 from 50

17 2011 LUTRO Luft- und Trockentechnik GmbH Page 17 from 50

18 Concepts for reducing the energy/power costs The current situation on the paint sector requires a steady and prospective development of technologies and plant designs from operators and manufacturers of painting plants in order to always guarantee optimal operating modes and economic success. At present, caused by the introduction of eco tax and increase in the operating cost generated by it, this primarily applies to the power consumption. For more than 45 years LUTRO is active in the painting plant sector and pioneer of innovative plant technologies (which has found imitators time and again) has been handling this topic for early on and has developed several variants for economical power consumption. Automatic flash-off function The paint booth can be switched between two paint jobs to flash-off function. In this case, the plant is operated with increased air temperature for reducing the flash-off period and thus effectively faster painting process. This switch-over is caused by simply pressing the key on the control panel of the control cabinet. Alternatively, this can also be done on a separate control panel in the booth. The further process is automatically executed by the PLC in the control cabinet. The switch-over takes place from the current operation. Energy saving/economy operation In addition, preparatory work for the painting process, which is executed in the booth, offers opportunity to save energy. Since the spraying is not done in the plant, the consecutive operation of the plant is also not necessary. Solvents are also not released. For this reason, when the compressed air is not accepted in the spraying booth, the booth is kept in the operation or shut down for an adjustable period. This is automatically detected and converted/reversed by the PLC plant control. The PLC can pre-program the time until the switch-over. This control, as also in case of the automatic flash-off function, effectively saves power and heating energy. The scope depends on the plant operation duration. Apart from these simple economy measures, which are programmed seriesequipped in the LUTRO PLC, there are further possibilities in the apparatus technology and cost more LUTRO Luft- und Trockentechnik GmbH Page 18 from 50

19 Frequency control of the ventilators Frequency controlled ventilators require certain precautions in the control cabinet design; however provide several advantages with it. These are for example: No current load peaks while starting the rotary current motors, since there is no one star delta transformation of the motors Reduction of the air output in the flash-off as also in the economy operation (for PLC pre-programmable percentage) The booth pressure can be regulated using the frequency control of the motors instead of using the otherwise customary power driven exhaust air regulation flap. This is not required at all. Advantageous in this control are the more exact booth pressure regulation, exclusion of a regulator as well as low air resistance in the exhaust air duct guide Following concrete economy options are more effective here: Reduced power connection outputs with accordingly low charges Low heat and power outputs in case of reduced air output Economy in the plant technology as no components are required Side effect of this plant design is not only the power economy but of course also the higher maintenance friendliness of the plant and economical operating mode using soft start of the units. Increased life and low wear and tear are the positive consequences. Not to be equated with the frequency control of the ventilators, is however the use of soft start devices for the motors in the control cabinet. Here the motors of the plant are started quite slowly; however the star delta transformation with the high current peak (which is responsible for the electric connection output) is retained. On the other hand the classic power economy measures that are used for years and are proven, which use the heat recovery systems, nonetheless remain effective Heat recovery systems These systems are installed in the fresh / exhaust air duct system. The heat of the exhaust air flow is used here in the spraying operation to preheat the cooler fresh air suctioned from outside. This relieves the installed air heating system and can be designed with smaller output at first place, and consequently reduces connection output and charges. In the repair plant area, LUTRO offers the counter current plate heat exchanger. Fresh and exhaust air flow are led past each other here, separated only through aluminum lamella used for the heat transmission. The effect is often reinforced here by ribs, however, increasing the air resistance and also acting as dirt pan mainly in the exhaust air area LUTRO Luft- und Trockentechnik GmbH Page 19 from 50

20 Counter current plate heat exchanger (System LUTRO) Plate heat exchangers offered by LUTRO avoid this problem by means of absolute smooth walls on the exhaust air side and thus provide optimum flow conditions on fresh and also exhaust air side. This feature should be noted particularly while comparing with the products of the competitors. Counter current plate heat exchanger (function principle) 2011 LUTRO Luft- und Trockentechnik GmbH Page 20 from 50

21 Recovery factors of approx. 42% to 50% are achieved here depending on the degree of contamination. Advantages of this LUTRO specific design are the lower contamination, easier cleaning option and longer service life. Preliminary filters are not necessary before the heat recovery in order to reduce the contamination. Naturally there are also no costs for replacement filters and maintenance. Both systems are designed as modules and hence easily usable and can be dismantled in the summer. It should be noted that the topic of energy saving offers several designed variants and options. However it appears to be essential to us that the clear and simple plant technology as well as simple controlling and handling at any moment must be maintained even in case of various options according to the apparatus and control technology. A clear presentation and operation on the control cabinet and above all the planning of the built-in parts, coordinated to the structural conditions are necessary. This happens in LUTRO painting plants by means of polished plant technology and PLC technology developed in-house, which can be adapted to each individual requirement. Simple operation and handling is possible using text display of the operating conditions as also operation by pressing the buttons on the control cabinet. Innumerable pilot lamps and adjusting knobs as in case of outdated control cabinets are only confusing and are avoided by using PLC. Years of practice has proven it best. Naturally the described systems and apparatuses are available not only for new buildings, but in principle can be retrofitted in existing older plants. Even if the specific plant conditions must always be taken into account again, in spite of everything LUTRO has the suitable solution LUTRO Luft- und Trockentechnik GmbH Page 21 from 50

22 Reference annex for car paints: LUTRO KSP 7 Technical Data Combined colour spraying and drying booths (Type: KSP 7 DT) Plant type KSP 7 BT/ UT Dimensions (internal dimension) 7,000 x 4,000 x 2,900 (LxWxH in mm) Air output (Supply / exhaust air) 24,.000 m 3 / h. / 23,500 m 3 / h. Motor output 2x7.5 kw Rate of fall of air (empty booth) Approx m/ sec. Air change Approx. 295-times / h Heating agent Gas, oil, direct-heating by gas Gate system 4-wing entrance gate with large glazing Filter ceiling Large-area filter ceiling with patented quick change system Paint separators Dry separator with Intensive extraction Control and regulating system PLC system (industrial standard) 2011 LUTRO Luft- und Trockentechnik GmbH Page 22 from 50

23 Dimension sheet KSP 7-BT (lateral view of air handling machine) Standard booth car repair booth with lateral view of air handling machine and WRG 2011 LUTRO Luft- und Trockentechnik GmbH Page 23 from 50

24 Image and reference documentation Reference customers from A - Z (extract) Overview of the list of reference customers Upon request, you can get reference customers from your branch and in your neighbourhood in our project department LUTRO Luft- und Trockentechnik GmbH Page 24 from 50

25 Preparation bays / peripheral equipment Type 1: Under floor extraction with fully gridded floor 1. Supply and exhaust air system with heating 2. Blowing-in duct with filter ceiling 3. Extraction 4. Adjusting flap with drive 5. Control panel 6. Curtains for the flexible separation of the work places 7. Mobile IR radiation field Preparation bays with fully gridded floor 2011 LUTRO Luft- und Trockentechnik GmbH Page 25 from 50

26 Type 2: Under floor extraction with partially gridded floor 1. Supply and exhaust air system with heating 2. Feed duct with filter ceiling 3. Extraction 4. Adjusting flap with drive 5. Operating panel 6. Curtain walls for the flexible separation of the work places 7. Mobile IR radiation field Preparation bays with partially gridded floor 2011 LUTRO Luft- und Trockentechnik GmbH Page 26 from 50

27 Type 3: Above floor extraction 1. Supply and exhaust air system with heating 2. Feed duct with filter ceiling 3. Extraction 4. Adjusting flap with drive 5. Operating panel 6. Curtain walls for the flexible separation of the work places 7. Mobile IR radiation field Preparation bays with supply air system and above floor extraction 2011 LUTRO Luft- und Trockentechnik GmbH Page 27 from 50

28 Credentials: Preparation locations with additional equipment 2011 LUTRO Luft- und Trockentechnik GmbH Page 28 from 50

29 Credentials: Preparation locations with additional equipment 2011 LUTRO Luft- und Trockentechnik GmbH Page 29 from 50

30 Preparation and spot repair work places LUTRO plant with integrated Vario Dry-Jet System 2011 LUTRO Luft- und Trockentechnik GmbH Page 30 from 50

31 Painting and drying plants for cars Combined spraying and drying booths with intermediate double dryer Spraying and drying booths with roller shutter, working platforms and cross-travel 2011 LUTRO Luft- und Trockentechnik GmbH Page 31 from 50

32 Painting center with above ground units [air handling machines] and integrated large capacity booth 2011 LUTRO Luft- und Trockentechnik GmbH Page 32 from 50

33 Combined spraying and drying booth for small parts, combi-booth with lateral double dryer Combined spraying and drying booth with lateral dryer and roller shutter 2011 LUTRO Luft- und Trockentechnik GmbH Page 33 from 50

34 Combined spraying and drying booth with lateral dryer and vertical lifting shutter Combined paint spraying and drying booth for small parts (LUTRO ECO 20, diagonal ventilation) 2011 LUTRO Luft- und Trockentechnik GmbH Page 34 from 50

35 Preparation bay with vertical lifting shutter for the combined spraying and drying booth 2011 LUTRO Luft- und Trockentechnik GmbH Page 35 from 50

36 Painting and drying plants for commercial vehicles In principle an individual, object and process specific plant planning is useful for large capacity painting booths for commercial vehicles. Normally large booth cross-sections quickly lead to high air volumes and power consumptions. Individual and requirement suitable planning represents the key to the optimum surface technology here. Different plant concepts are introduced below in brief; variations are the rule in the practice. Diagonal ventilation With a diagonal air circulation the system offers a simple and in particular also inexpensive solution for designing the plant. Here one distinguishes between a plant with a above floor version i.e. foundation or floor work is not necessary here, and a plant with a simple floor pit, which offers somewhat more favorable ventilation conditions. There is also a travel-through option, which can be very important for the work cycle. The diagonal ventilation is proven as extraordinarily affordable solution for companies, in which there is no continuous painting. Diagonally ventilated (under floor) Diagonally ventilated (above floor) Vertical ventilation The technically optimal solution is a plant with a vertical air flow. Here, LUTRO Company works on the principle that a fall rate of air of 0.15 m/s related to the free booth cross-section should be considered as minimum requirement. This value was specified in cooperation with different various specialised institutions (e.g. VDMA). In near future, a EC Guideline will surely replace the national guidelines. The fall rate of air can then be increased up to e.g. the magnitude of 0.4 m/s. These relatively high air outputs are generally provided in the production area with relatively high throughput. A value of about 0.2 m/s is used as basis in a repair booth. This is proven regarding the work conditions and also the paint quantities, which are processed, as a practical solution LUTRO Luft- und Trockentechnik GmbH Page 36 from 50

37 Image references of commercial vehicles Combined spraying and drying booth with dryer and working platform 2011 LUTRO Luft- und Trockentechnik GmbH Page 37 from 50

38 Combined spraying and drying booths for the painting of commercial vehicles 2011 LUTRO Luft- und Trockentechnik GmbH Page 38 from 50

39 Combined spraying and drying booths (Finish-painting of buses) Preparation bays and combined spraying and drying booth for commercial vehicles and buses 2011 LUTRO Luft- und Trockentechnik GmbH Page 39 from 50

40 Combined spraying and drying booths for rail vehicles Combined spraying and drying booths for helicopters 2011 LUTRO Luft- und Trockentechnik GmbH Page 40 from 50

41 Painting plant for concrete pumps Cleaning, painting and drying booths with manual overhead conveyor LUTRO Luft- und Trockentechnik GmbH Page 41 from 50

42 Painting and drying plants for industrial products More often the surface characteristics of a product play a crucial role for its prestige, quality and possible usability. With good surface technology, these can be used for good purpose and enable the separate optimization of surfaces and material characteristics. Considerable advantages can be achieved for surface-technically treated products against the untreated products. The right paint and the corresponding application method enable the use of favorable base materials, whose surface characteristics are adapted to the qualitative and functional product requirements. For more than 50 years, our planning engineers have worked out custom-made concepts for coating processes all over the world. Special references (industrial plants) A small selection of image references of our plants for the surface treatment of industrial products in the machine and plant construction is illustrated on the following pages LUTRO Luft- und Trockentechnik GmbH Page 42 from 50

43 Combined spraying and drying booths with conveyors and working platforms Flexible PLC terminal 2011 LUTRO Luft- und Trockentechnik GmbH Page 43 from 50

44 Combined spraying and drying booth with conveyor system (Trailer painting) 2011 LUTRO Luft- und Trockentechnik GmbH Page 44 from 50

45 Combined spraying and drying booth with ceiling division 2011 LUTRO Luft- und Trockentechnik GmbH Page 45 from 50

46 Combined cleaning booth and combined painting booth for large components Preparation, cleaning and painting booths for machine components 2011 LUTRO Luft- und Trockentechnik GmbH Page 46 from 50

47 Cleaning and combined painting booth for large engines 2011 LUTRO Luft- und Trockentechnik GmbH Page 47 from 50

48 Combined painting and drying booth with manual overhead conveyor 2011 LUTRO Luft- und Trockentechnik GmbH Page 48 from 50

49 Cleaning and combi-booth with crane flap for large pumps Phosphating and drying booth with ultra-filtration, painting and drying booth for hydraulic cylinders 2011 LUTRO Luft- und Trockentechnik GmbH Page 49 from 50

50 References to useful literature 1. Klima schützen Kosten senken, Energiesparen bei der Lackierung (ISBN ) [Protect climate lower costs, save power while painting (ISBN )] 2. BGI 740:2008 Lackierräume und einrichtungen für flüssige Beschichtungsstoffe [Painting areas and equipment for liquid coating materials] 3. EN 12215:2004 Beschichtungsanlagen Spritzkabinen für flüssige organische Beschichtungsstoffe Sicherheitsanforderungen [Coating plants Spraying booths for liquid organic coating materials safety requirements] 4. EN 13355:2005 Beschichtungsanlagen Kombinierte Spritz- und Trockenkabinen Sicherheitsanforderungen [Coating plants Combined spraying ad drying booths safety requirements] 5. EN 1539:2000 Trockner und Öfen, in denen brennbare Stoffe freigesetzt werden Sicherheitsanforderungen [Dryers and ovens, in which combustible materials are released safety requirements] Disclaimer This publication is based on empirically established figures in our company as well as on generally accessible sources that cannot always be verified by us, which we consider reliable, however we cannot be held responsible if they are not correct and complete. This publication is no substitute for the personal consultation. It is used only for information purposes and is not regarded as offer or request for the purchase or sale. Please contact our project-department for further individually designed and more current information about concrete plant concepts and for the purpose of individual consultation. Our opinion expressed here is subject to change anytime and without prior announcement. Update of this information is also subject to cancellation and discontinuation without further prior announcement LUTRO Luft- und Trockentechnik GmbH Page 50 from 50