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Flexible solution for challenging coating applications
A clever mix of automated and manual application proscecces at the new Paint Shop of ISMM in Czechia enchances the comapnies production capabilites significantly.
At ISMM Production & Business Cooperation s.r.o.in Město Albrechtice, Czechia, a completely new coating system was recently installed, which was specially designed for coating steel products. With its combination of manual and automated processes, it complements the existing infrastructure and is designed for components with maximum dimensions of 7,000 mm in length, 2,000 mm in width and 3,000 mm in height. The installation took place in a production hall that already had a coating line for smaller products. However, the new line is independent and has been completely rebuilt to meet increasing requirements.
The project presented a number of challenges. For example, the height was limited to 5.7 metres, and the system had to be installed in an area measuring 35 × 11.5 metres without affecting the existing systems. This required precise planning, particularly for the positioning of the combined washbox unit and spray booth. The integration of the lifting systems for product handling and the static calculations for the steel girder structure were also challenging.
The painting process
The coating system covers the entire process chain, from cleaning the components to the final coating and curing. The process begins with a blasting station, where contaminants and surface residues are removed from the components. Manual blasting is carried out with abrasive materials, followed by thorough removal of the residues. The components are then loaded onto the overhead conveyor, which transports the products through the other stations.
The chemical pre-treatment takes place in an automated ‘wash box’ that integrates several steps. First, the components are degreased to remove residues such as oil and grease. This is followed by rinsing with tap water, followed by rinsing with demineralised water, which guarantees a particularly clean surface. Finally, the products undergo a passivation stage, which protects the components from corrosion and ensures optimum adhesion for the powder coating. A special feature of the ‘wash box’ is the integrated hot air drying system, which reaches temperatures of up to 80 °C. After chemical treatment, air circulation is automatically activated to dry the components efficiently and prepare them for the subsequent coating steps. A magnetic grid is installed in the drainage area of the pre-treatment stage to collect steel dust that is washed off the components after blasting. These grids can be easily removed and cleaned for maintenance, ensuring a high degree of efficiency.
Powder coating is carried out in a manual spray booth that is specially designed for flexible applications. The coating itself is applied using the ‘Inocart Vt’ electrostatic powder coating system from Sames Kremlin. Thanks to the vibration system, there is no need to transfer the powder coatings to separate containers, which speeds up the process and simplifies colour changes. The twelve-metre-long powder feed hose allows the operator to move freely around the component, while the system is certified for use in safety-critical EX zones. Powder coating is carried out entirely manually, with the layer thickness being individually controlled to meet customer requirements. The exhaust air is passed through a system of double end filters, each with a capacity of 16,000 m³/h. The filter units operate at a power of 22 kW each and ensure that the air is effectively cleaned and emissions are minimised.
The final stage: curing
The coating is cured in a directly gas-heated convection oven. The oven is designed as a single chamber and has space for three product trolleys. The central position is designed for larger components, while the side positions are suitable for narrower components. The oven can reach temperatures of up to 230°C and allows flexible curing depending on product requirements. The curing time varies between 20 and 40 minutes, depending on the size and complexity of the components. Each oven module is equipped with a powerful air circulator that ensures even heat distribution. Safety systems and temperature controllers are also integrated.
The entire plant is monitored by the “HiVision” system, a software platform that provides real-time data and supports preventive maintenance. The system enables integration with ERP systems as well as cloud-based data access and IoT connectivity. It continuously records data and identifies trends that are helpful for optimisation and fault prevention.
Training for safe operation
Before commissioning, employees received comprehensive training on how to operate the plant safely and efficiently. The training covered the operation of the individual technological units, troubleshooting and preventive maintenance. In addition to on-site training, remote support is also offered. Depending on production capacity, between three and six employees work in the coating plant, controlling and monitoring the individual steps of the process.
The total investment for the new paint shop amounted to approximately €1 million. With its process structure and integrated technological solutions, it expands ISMM’s production capacities and offers a reliable solution for coating steel products used primarily in the agricultural machinery, automotive and material handling industries.
More information: IDEAL-Trade Service, www.itsbrno.cz/de