SPRAY PAINTING SYSTEMS

Transcription

1 Sumko Engg. Sys. B/6, Bush Villa Society, Road No 22, Wagle Estate, THANE Tel: (022) Telefax: (022) Visit us at SPRAY PAINTING SYSTEMS PRE TREATMENT PLANTS SPRAY PAINTING BOOTHS

2 You Can Afford The Best We, at SUMKO, manufacture full range of spray painting systems - booths, conveyors, floor trolleys, ovens and pretreatment plants. Our experience of more than two decades guarantees innovative designs matched with quality and economy. Thus we understand your needs better than anybody else. We, at SUMKO, aim for practical and cost effective, energy efficient designs for any and every application of yours - batch or conveyorised. We, at SUMKO, aim for practical and cost effective, energy efficient designs for any and every application of yours - batch or conveyorised. Let us meet to execute your plans SUMKO ENGG. SYS. where COMMITMENT IS THE STRENGTH

3 SPRAY PAINTING/POWDER COATING PLANT A spray painting plant is a cluster of equipments designed for specific component or components so as to achieve required production rate. The basic objective behind design and installation of the plant is to use the minimum floor space, streamlined production, efficient material handling, ease of operation, optimum running cost and the highest quality of surface finish. The plant can be designed either for batch type of operation or for the mass production; depending upon the rate of production. In broad terms a spray painting plant consists of following equipments: Pretreatment Plant Spray Painting Booth. Flash off Enclosure Paint Drying Oven. Material Handling System Electrical Control Panel. Other than these basic equipments; depending upon requirements other utility equipments that form a plant are: Air Supply or Replacement Plant Indirect Heating System for Oven. i. Hot Air Generator with LPG or LDO/HSD as fuel. ii. Thermic Fluid Boiler with LDO/HSD as fuel. iii. Hot Water Boiler with LDO/HSD as fuel. D I or D M Water plant. Water Softening Plant; if required. Air Compressor. Effluent Treatment Plant. We, at Sumko Engg. Sys; can supply any type of painting plant on turnkey basis. Based on your production rate and the component size; we can design, manufacture, supply and install the plant at your premises, within shortest possible time. We ensure that the plat design is optimum, its running cost is minimum and material-handling system is easy to operate.

4 Why to install a spray-painting booth? 1. LAW Under the Factories Act, it is Statutory requirement to install adequate ventilatory equipment at the place of spray painting operation. 2.POLLUTION The air exhausted from the painting area Should be free of paint. Only a properly designed and an efficient spray painting booth ensures this and exhausts clean air into the atmosphere without polluting it. 3. SAFETY Over sprayed paint, if allowed to settle down in the painting area, it is fire prone and hazardous. It also stinks and gives a bad look to the whole area. 4. QUALITY OF WORK If a filtered air set up is added to the spray booth, it removes all the dust and the other particles and supplies clean air to the painting area. This enhances the painting quality as also the productivity. 5.OPERATOR COMFORT Painting operator receives continuous supply of fresh air. This ensures his proper mindset and indirectly helps in increased efficiency.

5 STANDARD WATERWASH SPRAY BOOTH How does it work? Air containing over spray paint particles enters the extraction chamber between the entrainment plate and the water surface at very high velocity. Immediately, it undergoes two directionally changes, rapidly; mixed with the centrifugal force. As such, solid particles from paint get thrown away into the water stream. These solid particles get settled on the base plate. The air with the water droplets raise above; towards the exhaust fan. The water droplets get eliminated from the air, when it hits bottom of eliminator plates and it falls down on the base plate. This water, on its return path carries solid particles of the paint, to the bottom of the water tank via return trough. Thus, paint and water free air passes through the exhaust fan and only air is exhausted into the atmosphere.

6 The water wash spray booth does not have a water screen or pump and it s piping. In lieu of that it employs a high-pressure centrifugal air exhaust fan, which forces the air to pass at very high velocity across the water surface of the water tank. This results in shearing of the water surface and the water droplets get entrapped into the air. The over sprayed paint gets embedded into this water-air mixture. This mixture is then allowed to enter into the extraction chamber via distribution plate; which applies centrifugal force on it. After that it is then made to follow a torturous path inside the chamber where there are very swift directional changes. Firstly, the centrifugal action creates an area of high turbulence; thereby the paint laden air-water mixture gets scrubbed vigorously. Because of this repeated scrubbing action, the resin from the paint, gets recirculated and eventually is broken down. The pigment particles from the paint gets settled down on to the base plate as a non-sticky substance and can be disposed off easily during the maintenance of the booth. Water treatment The synthetic enamel paints are resistant to alkaline attack. So it is important to attack the whole surface area of the paint particle for a prolonged time. That means, the paint particles should not allowed to get clogged inside the painting booth. This is simply achieved by adding mineral oil into the water. The oil, being lighter than water; floats on the water surface. The paint particles, faces the first attack of the alkali when it gets mixed with the water and air at the water surface of the tank. The oil film; preventing it from clogging, immediately engulfs it. The recirculation of these particles forces them to pass through the oil film again and again, thereby increasing the no. of alkali attack on them. Less maintenance As this spray painting booth does not employ pump, piping or nozzles and the water screen or the filter, nothing gets clogged. Further as the over sprayed paint gets oil film protection, they are prevented from getting stuck on the extraction chamber inside or the bottom of the water tank. This reduces the chances of breakdown or the down time to the absolute minimum. Further, as the non-sticky pigment particles are carried to the bottom of the tank, via return trough; it gets settled down there itself. Since the over spray enters the chamber at the water surface level, there is no chance that these non-sticky slit gets disturbed and mixed again into the water. Thus the only maintenance in this type of spray painting booth is periodic removal of this non-sticky slit from bottom of the tank. Clean air Once, the paint particles are broken down and pigments allowed to drop on the base plate; the remaining air-water mixture passes through the narrow gap of opposite direction formed by the eliminator plates. The heavies water particles, due to impact and obstruction gets removed from the mixture and only clean air is allowed to enter the exhaust fan; which is then exhausted to atmosphere. Summary of advantages 1. Less capital cost due to doing away of pump, water screen and piping. 2. Advanced water treatment ensures total break down of paint. 3. No breakdowns due to clogging 4. Less or negligible maintenance. 5. Economical to run the booth as less electrical power is consumed. 6. Due to it s compactness; requires less floor space. 7. No air pollution because of complete breakdown of paints. 8. No fire hazards, as pigments are non-volatile. 9. Easier to operate and maintain. 10. Enhances operator confidence thereby increasing his efficiency

7 STANDARD SIDE DRAFT SPRAY BOOTH These Water Wash Spray Painting Booths meet most industrial finishing requirements. The fresh air flows from behind the operator; across the component towards the extraction chamber. That is reason, they are known as SIDE DRAFT booths. The booth is formed of mainly OUR parts. Firstly, a WATER TANK. On the top of water tank is EXTRACTION CHAMBER. Further to extraction chamber is PAINTING AREA. The EXHAUST SYSTEM is placed on top of the extraction chamber. These booths are generally manufactured in standard width of 100 mm and in increments of 100 mm. The total depth, inclusive of extraction chamber is normally 2400 mm and the painting area depth is 1650 mm. These booths are available in standard painting area height of 2100 mm. Therefore, except width of the spray booth all other sizes remain standard. That is the reason, when booths are discussed, width is mentioned. Although, the standard width available is in multiple of 1100 mm; special width booths can also be designed and manufactured. Also special booths for low ceiling height can be designed for a specific requirement.

8 STANDARD SIDE DRAFT SPRAY BOOTH The standard water wash side draft booths are available in following sizes: WIDTH TOTAL TOTAL EXHAUST MOTOR PAINTING DEPTH HEIGHT FAN kw/ HP AREA (D*W*H) / *900* / *1100* / *2200* / *3300* / *4400* / *5500* / *6600* / *7700*2100 QUALITY and TRUSTWORTHYNESS is backbone of our policy. This guides us to stand firm in our motto of not compromising on the technical/manufacturing parameters. Nor do we get tempted to use sub-standard raw material or bought out items to cut down our costs. We do not believe in offering our products at lower cost at the expense of compromises on quality. Because we know, the client wants products of high standards and he is ready to pay little extra if product is genuine. That helps us in standing apart from all others. Along with the painting booth following accessories can be supplied: a. Turn table for painting of the component. b. Rotating device for hanging of the component inside the booth. c. Dustproof fluorescent lighting fixture. We deliver what we promise. And we promise following: 1. Water tank, extraction chamber and its components shall be manufactured from 2.00 mm thick CRC MS sheets. 2. Painting area components shall be manufactured from 1.6 mm thick CRC MS sheets. 3. The electrical items: Electrical motor : ABB/Crompton/LHP Motor Starter: : L&T/Siemens Cable: : PVC armored Copper 4. All the components shall be properly chemically treated and painted with the enamel paint.

9 CONVEYORISED WATER WASH SPRAY BOOTH Useful for handling of component passing through booth on conveyor These booths are designed for mass production, where overhead conveyor passes through the spray painting booth along its width. The painting can be either manual or automatic. At both ends of the booth, vestibules are provided. They ensure airflow into the booth and reduce the chances of over spray from painting area getting mixed into the atmosphere. Width Exhaust Fan Motor A B C G F Qty HP

10 Sumko BENCH TYPE SIDE DRAFT SPRAY BOOTH The standard type of side draft spray booth; at times, is not suitable to facilitate the painting of small components. It requires more floor space, it is very inconvinient to relocate it and it consumes more electrical power. Further, a prospective buyer; who wishes to paint small and tiny components; feels it too big and unuseful to him. To overcome this feeling; we have developed a small and tiny bench type of side draft spray painting booth. SPECIAL FEATURES Painting area 900 x 900 Leg supports for better stability Exhaust Fan dynamically balanced Consumes lesser power HP. Better air flow, creates feel good factor for painter. 1. Leg support in height. 2. Water Tank for effective water wash effect. 3. Painting area where component is painted 4. Extraction chamber heart of the system. 5. Exhaust fan the only rotating/moving part. TECHNICAL SPECIFICATION: Working size : 900 W x 900 D x 900 H Exhaust fan : 2.00 HP, Centrifugal, direct driven. Motor : CROMPTON / ABB LHP Construction : MS 2.00 mm thick CRCA. Painting : Either oven painted or powder coated. Following accessories are necessary for the ease of painting: 1. MS grill above the water tank in painting area mm dia rotating table - component can be placed on the table, which can be rotated. 3. A rotating device - 10 Kg capacity - component can be hanged on it. 4. Fluorescent lighting fixture - this can be fixed on the painting area top panel or kept at inclined position below the nameplate.

11 Sumko DOWNDRAFT WATERWASH SPRAY BOOTH Useful for large and heavy components difficult to handle These booths are specially designed for large and heavy components, which are difficult to handle; like tractors, chassis of vehicles, trailers, earth moving machineries etc. The fresh air flow; in this type of painting booth is from top to bottom. The water tank is placed underground; it can be either alkaliproof RCC of fabricated out of MS plates. Depending on the size of the component, these booth can be single sided or the double sided. Which means; there shall be single or double extraction chamber, on either one side or both the sides of the component. The fresh air coming from top of the booth takes away the over spray paint particles through metallic grill towards the water tank for further water wash process. The water treatment being same as that in the side draft booth. The heavy and large components are placed centrally in the painting area; either on the floor or material handling trolleys, the operator can move around all the sides of the component. Thereby, the whole surface of the component can be painted without any further material handling or rotating of the component. The double sided down draft booth has two underground water tanks and two extraction chambers in between the painting area. The component can be pushed into the painting area through the entry exit doors. The painting area length and the width depend on the size of the component to be painted. For underbody painting, like that of railway wagon or container; a center pit with air supply can be provided. The single sided down draft booth has single water tank and extraction chamber. This means the air suction is only from one side. This is little inconvenient for the operator; but it saves the capital cost.

12 PRE-TREATMENT PLANT A process to be adopted before painting. Any metallic surface shall have dirt, rust, carbon black particles or thin layer oil deposited on it. It can be any of these or all of these. Before we apply paint on any surface, ether by brush or spray it, it is very much essential to remove these deposits and prepare the metal surface. The process, which removes the traces of oil, rust, dust or other deposits by chemical action, and allows the formation of crystalline phosphate layer on the metallic surface, is a Pre-treatment Process. The crystalline phosphate layer; on the surface, increases the bond between the paint particles and the metallic surface; thereby extending the life of dry film of the paint. The main process stages which are essential: DEGREASING: This is an alkaline chemical bath, which removes any traces of oil film from the metallic surface. A hot degreasing stage gives better results and production rate. The temperature of the bath is between C. DERUSTING: This is acidic bath, which removes rust and carbon black particles from the surface. Here also, if the bath is heated up, it gives the best result. But at the same time, the hot acid generates more fumes, thereby corroding the plant structure. So a balance has to be chosen between the cold and hot derusting. The temperature of the bath is between C. ACTIVATION: This stage assists in forming a better phosphate layer on the surface. PHOSPHATING: This can be either zinc phosphate or the iron phosphate. It gives better result when bath is hot. The temperature of the bath is between C. PASSIVATION: The phosphate layer is highly oxidant prone. So it is essential to passivate this layer. This is also a hot bath, temperature being in the range of C. GENERAL: The temperature of the bath, its concentration and the time for each stage depends on the metallic surface, the thickness and the amount of deposits etc. The chemical supplier decides this. In order to avoid mixing of various bath chemicals into each other a single or double water rinsing stage is added between each chemical stage. The PT plant can be designed for batch type or mass production. In the batch type plant, the process is dip type; wherein components are placed inside a cage. This cage is then dipped into the tank containing the chemical bath. This type plant consists of tanks, overhead mono or double rail and traveling hoist or transporter system for material handling. When the production volumes are large and the components are easy to handle; they are placed on the overhead conveyor and the chemical or water is sprayed on to the component. This is totally automatic operation and plant consists of tanks, circulating pumps and piping, spray nozzles, the collection trays, spray tunnel and the overhead conveyor.

13 PRE-TREATMENT PLANT A process to be adopted before painting SPRAY PRE-TREATMENT For mass production, a spray type pretreatment plant can be designed. Here, components are hanged on an overhead conveyor; which passes through a MS/SS enclosure. Specially designed spray nozzles are fitted on the pipes to form a ring around the component. Depending on conveyor speed and time required for chemical process; no. of rings are placed one after another for each stage. Two stages are separated by a drip or drain zone; where sprayed chemical is allowed to drain off the component. The sprayed chemical is collected in the drain pan and further directed into the tank. This is again sprayed on to the component by chemical circulation pump. The entire stage enclosure is fabricated out of MS or SS as per the requirement. The type of spray nozzle, it s capacity, material of construction etc. changes from stage to stage. This is a totally automated process and manpower is required only at the loading and unloading point. Further, since this is an automated process; it gives enhanced quality and uniform phosphate grain layer all around the component. DIP PRE-TREATMENT This is a conventional pre-treatment wherein the plant cost is less and is suitable for low volume production lines. The chemicals are stored in the MS/SS fabricated tanks. The components are placed in the baskets or cages and they are dipped in each process tank for pre-fixed period of time. The movement of the basket or cage can be either manual; with a monorail and hoist or automatic with a transporter system. Since this is a manual or semi-automatic process; the quality of the phosphate grain layer is not uniform. Further, as chemical tanks are open; the heat losses from hot tanks are more. The chances of inter-mixing of chemicals from one stage to other cannot be avoided; also because of dripping and splashing, losses of chemicals are also more. But, since the plant and running costs are low, it is suitable for low volume production.