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FLUID BED - COATING SOLUTIONS

Vertical Fluid Bed Plant Complete for Panel and Posts up to 3,6 meter and Static Spraying of Posts to 7 meter.

PRODUCT DIMENSIONS:

  • Height — 3,000 mm
  • Length — 3,000 - 7,000 mm(fencing and posts)
  • Width — 100 mm per panel/post
  • Max Weight — 40kg/panel x 4 = 160kg
  • Conveyor Speed — 2.0 - 7m/min variable and indexing for the dip application
  • Parts per hanger (spraying) - 2 off fencing panels or +/- 8 off 7m posts in horizontal position
  • Parts per hanger (Dipping) — 4 off fencing panels or 4 - 6 off 3,6m posts in the horizontal angled position
  • Production Rate (Spraying) — Panels: +/- 2 parts @ 5 min = 24 panels/hour
  • Production Rate (Dipping) — +/- 4 parts @ 5min = 48 panels/hour
General arrangment of the plant components

Conveyor System:

  • The conveyor system will consist of JK track, chain, pendants, conveyor legs, drive unit and auto lubricator.
  • Bendet will supply load bars and dip bars for all the index positions (+/- 17 off).
  • Bendet will supply a transporter dipping device that will run on the same tracks as the booth removal system.

Pre-treatment System:

  • The system will include two wash stations suitably spaced to allow functioning for the indexing (Dipping) as well as the continuous (Spraying) system.
  • The first stage will be a degrease phosphate stage and the second stage will be a rinse stage.
  • The system will include DAB type pumps (pool pumps) which will be used to spray the phosphate and rinse in the spray tunnel.
  • The spray tunnel will be constructed from stainless steel and polypropylene and all piping will be PVC.
  • The spray nozzles will be off the clip eyelid type and will be fully adjustable.
  • The system will have an electrical high-pressure blower that will be installed after the final rinse to blow off excess water from the parts before moving it to the pre-heat oven.
  • There will be an extended drip section to allow for extra dripping time upon exit of the spray tunnel.
Pre-treatment section

Pre-heat and Curing Oven Description:

  • Type of oven: Single pass through oven.
  • Location: The LPG package burner and air recirculation unit will be housed above the oven.
  • Zones: 1 (LPG Convection).
  • Heater transfer to objects: By convection and Electrical Elements.
  • Heating medium: LPG package burner.
  • Booster Zone - Exit: Electrical Elements +/- 60kW (Pre-heat), 36kW (Curing).
  • Air Seals: 2 air seals at each end.
  • Door: Pneumatically opening doors at each end during the indexing cycle (dipping) for power saving.

Technical Data:

  • Active length of oven: +/- 13600 mm.
  • Object temperature: Up to 270°C.
  • Re-circulating air temperature: Up to 350°C.
  • Total time in oven: 13.6 minutes @ 1m/min and 15 minutes @ 5min cycle for dipping.
  • Thickness of insulated panels: 150 mm for pre-heat and 100mm for curing.

Manufacturing description:

The oven tunnel is a self-supporting construction and consists of 150 mm thick insulation panels for the pre-heat oven and 100mm for the curing oven. The insulation panels are manufactured as sheet metal cassettes. The panels are fitted together by means of tongue and groove joints with a sealing groove, i.e. no clamping devices or screws are required. High-density resin-bonded fibreglass material is used for insulation. The insulation material is 100kg/cub meter density.

Heater and re-circulatin unit technical data:

  • Number of Units: 1
  • Heating medium: LPG.
  • Installed capacity: 200 - 300 kW each.
  • Re-circulating fan: type BCC.

Description of operation:

  • Air heater and re-circulating fan is assembled as one unit.
  • Special care is taken to ensure easy access to the individual items of equipment.
  • The insulated unit is integrated above the oven tunnel.
  • The heater unit is of compact design.
  • The temperature monitoring and control will be by means of a temperature controller and Type J thermocouple.
Typical pre-heat and curing oven

Powder Booth:

Our powder booth, cyclone and reverse pulse unit is locally designed where we are using the latest Solidworks 3D package, utilizing the flow analysis software. We can do simulations right down to the smallest particle size with all the fan pressure and flow curves integrated into the design. This allows us to get the optimum powder recovery out of the system. The cleaning hatches are strategically placed to improve the colour change time. The booth environment must be draught free. The air speed around the booth must be less than 0.1m/s in order to avoid powder escaping. The operators must take care of the direction of the powder gun when applying powder so as to not direct it out of the powder booth.

Flow analysis software
Powder booth auto-manual assets

Quick on-off Booth including all manual application equipment and powder recovery to the cyclone hopper. The understanding is that the complete part/s must be coated and based on the discussions many parts can be coated automatically by dipping and some parts will be manually coated by operator spraying the parts. The system is designed to be able to cater for 3 colours 􀂱 but the current requirement is for a single colour only. The system will cater for powder recycling. The parts are transported to this booth via an overhead conveyor in order to be coated by 2 manual guns. This booth is ventilated by one standard fan/filtration group with a manual cyclone recovery package. At the booth entrance and exit, one manual sprayer station would be located at each end, featuring two manual spray guns. The supply air flow is spread all along the booth through the central conveyor slot, allowing for a good distribution of the extraction air flow within the enclosure while meeting the application and cleaning constraints. The extraction air flow will be on the floor of the booth where the floor will be slanted towards the extraction point. A manual powder recovery system comprising of a Venturi Pump which reclaim powder from the cyclone back into the gun or fluidized bed hopper. The system will have a dedicated HMI controller unit installed.

Standard equipment included for the booth:

  1. 1. 1 off booth constructed from mild steel which is powder coated.
  2. 2. Standard Ducting and Cyclone recovery system.
  3. 3. Standard Reverse Pulse filter unit.
  4. 4. Powder pump connected to the powder hopper.
  5. 5. 2 x Manual powder systems complete with gun controller, powder venture pump, powder hose and accessories to suit.

Basis of Design – Fluidized Bed Section

Product Dimensions:

  • Height : 3,000 mm
  • Length : 3,000 mm (Fencing)
  • Width : 100 mm x 4 fences
  • Max weight : 160 kg
  • Conveyor speed : indexing for the dip application
  • Parts per hanger (Dipping) : 4 off fencing panels
Typical 3D design of clip section

Complete transporter system that will include:

  • Steel frame and rails complete with hoist section;
  • Braked hoist motor and gearbox;
  • Braked travel motor;
  • Travel rail;
  • Electrical panel on board with electrical limits and interfacing to the remote PLC;
  • Manual and auto operation;
  • Vibrating lifting jaws.

Fluidized bed tank frame and trolley (Optional for multiple colour systems):

  • Drive motor and gearbox;
  • Trolley frame;
  • Trolley floor rail;
  • Electrical components and cabling.

Additional ducting to fluidized bed area:

  • Ducting above tank;
  • Ducting supports;
  • Ducting to the powder booth cyclone.

Fluidized tank (1 off complete)

  • Steel re-inforced polypropylene fluidized tank including the fluidized bed;
  • Regulators and pneumatic spring coils;
  • High Pressure fluidizing pump;
  • VSD for fluidizing pump.
Typical fluidized tank dipping transporter

Dedicated Pole Fluidized Post dipping Line for 6,5 meter Posts

PRODUCT DIMENSIONS:

  • Height — 100 mm
  • Length — 6,500 mm
  • Width — 100 mm
  • Max Weight — 15kg/post (10 posts per bar)
  • Conveyor Speed — 3.0 m/min variable and indexing for the dip application
  • Parts per hanger (Dipping) — 10 off posts per bar
  • Production Rate (Dipping) — +/- 10 parts @ 15 min = 40 posts/hour

Complete Auto Line with Pre-Treatment and fluidized dip tank for 3m posts shown below – dimensions will be upgraded to accommodate 6,5 meter posts.

Complete auto line with pre-treatment fluidized dip-tank

PRODUCT DIMENSIONS:

  • The conveyor system will consist of medium-duty track, chain, pendants, conveyor legs, drive units and auto lubricators;
  • Bendet will supply load bars and a single dip section for all the index positions;
  • The conveyor will cater for a loading area and will then continue into the pre-treatment section where it will be degreased/phosphate and then rinsed in the same position;
  • The next index will move the parts from pre-treatment to the drying/pre-heat oven;
  • In the next index the parts will be positioned over a fluidized bed for PVC application. The bed will be raised and lowered for the PVC application. The parts will continue into the curing oven as part of the cycle;
  • The powder will be recovered by an extraction system that will comprise of a hood, ducting, recovery cyclone and a reverse pulse air filter;
  • The conveyor will index and continue to the off-loading section.

Pre-treatment system:

  • The system will include two wash stations suitably spaced to allow functioning for the indexing;
  • The first stage will be a degrease phosphate stage and the second stage will be a rinse stage;
  • The system will include DAB type pumps which will be used to spray the phosphate and rinse in the spray tunnel;
  • The spray tunnel will be constructed mainly from polypropylene and all piping will be PVC;
  • The spray nozzles will be off the clip eyelid type and will be fully adjustable;
  • The system will have an electrical high-pressure blower that will be installed after the final rinse to blow off excess water from the parts before moving it to the pre-heat oven;
  • There will be a drip tray between the pre-treatment section and he pre-heat oven.

Pre-heat and Curing Oven Description:

  • Type of oven : Single pass through in-line oven;
  • Location : The electrical elements and air recirculation units will be housed below the oven;
  • Zones : 1;
  • Heater transfer to objects : By convection and limited radiation;
  • Heating medium : Electrical elements;
  • Air Seals : None – only directional air flow;
  • Door : Manual opening doors at each oven opening for energy saving.

Technical Data:

  • Active length of oven : +/- 7 m;
  • Object temperature : Up to 300°C;
  • Re-circulating air temperature : Up to 340°C;
  • Total time in oven : 6-10 minutes @ 6-10 min cycle for dipping / curing;
  • Thickness of insulated panels : 100 - 150 mm.

Manufacturing description:

The oven tunnel is a self-supporting construction and consists of 100 - 150 mm thick insulation panels for the oven. The insulation panels are manufactured as sheet metal cassettes. The panels are fitted together by means of tongue and groove joints with a sealing groove, i.e. no clamping devices or screws are required. High-density resin-bonded fibreglass material is used for insulation. The insulation material is 100 kg/cub meter density.

Heater and Re-circulation Unit Technical Data:

  • Number of Units : 1
  • Heating medium : Electric Elements
  • Installed capacity : ___ kW each
  • Re-circulating fan : Depending on final design

Description of operation:

  • Air heater and re-circulating fan is assembled as one unit;
  • Special care is taken to ensure easy access to the individual items of equipment;
  • The insulated heater unit is integrated below the oven tunnel;
  • The heater unit is of compact design;
  • The temperature monitoring and control will be by means of a temperature controller and Type J thermocouple.

Fluidized tank system:

  • The system will include a dip tank station suitably spaced to allow functioning for the indexing;
  • Dipping of the parts will be automatically done;
  • A rotating action will be incorporated into the pole jig to remove excess powder or a suitable vibrating devise will be incorporated for the same function;
  • The system will be fluidized by a high-pressure fan system;
  • The fan motor will be controlled by a VSD

Electrical System:

The complete plant will be controlled by PLC and have an HMI unit which will cater for:

  • Easily accessible operator screens;
  • Alarming;
  • Trending;
  • Plant settings;
  • Recipes

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