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Increased productivity with closed-loop layer thickness measurement
Metallbeschichtung Südpfalz in southern Germany has successfully implemented a comprehensive retrofit project. By integrating the ‘coatmaster Flex’ into a closed-loop system, the company has optimised its powder coating processes.
Metallbeschichtung Südpfalz relies on state-of-the-art coating technology for powder coating in window and façade construction and in the automotive industry. Metallbeschichtung Südpfalz has been working with Binks (formerly MS Oberflächentechnik) for 25 years. A comprehensive retrofit project was implemented in cooperation a year and a half ago: new guns, an updated control system and, above all, the integration of the ‘coatmaster Flex’ into a closed-loop system. After eighteen months of continuous operation, those responsible are now taking stock.
Measurement directly on the component
The system continuously measures the layer thickness – five values per component side. Extreme values (minimum and maximum) are filtered out, and the average value from the remaining values automatically controls the powder output of the system.
A decisive advantage: control takes place directly on the component. This is because it is not enough to keep the powder output of the gun constant – between constant output and actual coating thickness on the workpiece lies the so-called application efficiency. This depends on numerous factors, such as the component geometry, the powder composition or climatic influences.
Only when the layer thickness is measured and controlled directly on the component can a consistently high quality be ensured. Tangible savings and greater safety Powder consumption is significantly reduced as excessively high or low layer thicknesses are avoided. Experience shows savings of 10 to 20% in powder consumption – with a direct impact on costs, sustainability and the carbon footprint.
At the same time, waste is reduced as undercoating is virtually eliminated. This makes the system more stable, more efficient and less dependent on the experience of the operators. ‘It was important for us that the requirements of the respective quality associations were met and that the coating thicknesses remained constant. The closed-loop system gives us the assurance that our customers receive only first-class goods,’ emphasises Steven Poth, authorised signatory and partner at Metallbeschichtung Südpfalz GmbH.
Proven technology
Partner company Binks also draws a positive conclusion. „The project at Metallbeschichtung Südpfalz impressively demonstrates how retrofitting and digitalisation can work together. Modern measurement technology and intelligent control not only ensure product quality, but also increase the productivity of the entire plant,“ says Manuel Kluckner from Binks. The technology is not a one-off: Binks has been actively offering the closed-loop system for around 18 months and, according to its own information, has already successfully implemented 20 retrofit projects during this time. Feedback from the industry has been consistently positive – from reduced raw material costs to greater planning reliability.
Automation creates process reliability for employees on the line. They can rest assured that the plant will operate reliably within specifications. Errors caused by manual readjustments are now a thing of the past.
More information:
Binks Switzerland AG: www.binks.com,
Coatmaster AG: www.coatmaster.com