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Plastic painting

When it comes to painting plastic components, Eisenmann is considered a leading systems supplier: One in two bumpers worldwide has been through an Eisenmann painting plant. With about 40 years of experience and extensive know-how acquired in the course of installing approximately 350 plastic painting plants around the world, Eisenmann boasts top quality in the sector, too.

The foundation for an immaculate paint job, especially for metal or plastic parts, is thorough pretreatment and primer application.

CO2 cleaning
CO2 snow cleaning has established itself as an energy-efficient alternative to wet chemical pretreatment. This technique eliminates the need for the energy-intensive steps of drying and cooling the parts before they can be treated. The only waste produced is the dirt blasted off the parts. The air flow in the booth and in the inlet and outlet seals is critical for the cleaning results.

Spray Pretreatment
For metal and plastic parts that cannot be immersed, Eisenmann also builds plants for chamber pretreatment and continuous pretreatment. A special focus is placed on the optimization of water consumption. The result is a significant cost savings on both fresh water and waste water purification.

Our selection spans the full range of complete solutions for sub-suppliers and manufacturers of products made of plastic and new materials. The plants feature the latest application engineering technology, intuitive controls and intelligent and material-conserving supply systems. The result is a maximum of efficiency and a minimum of resource consumption in production.

Atomizing
The VarioBell v.2 and VarioBell v.3 atomizers are among the most cutting-edge high-rotation atomizers in the world. Thanks to their lean design, light weight and dual shaping air system, they are perfect for coating undercuts, as well as painting large exterior surfaces. They allow for direct charging of both 1K and 2K water-based and solvent-based coatings and achieve top application efficiency.

Potential isolation
The VarioCharger system ensures reliable potential isolation in conjunction with precise paint dosage. As a result, even conductive water-based coatings can be applied to a part using a direct charge. This piston-based system also features a compact and simple design and is extremely low-maintenance.

Paint supply
Eisenmann supplies both high-runner systems and special paint supply systems such as TPS (tracking paint supply) and EasyPig. These technologies help stabilize the processes and ensure optimal paint quality. The pigging system ensures low material consumption and easy, flexible handling. All the units feature a compact design and provide reliable and adequate material supply for coating application systems.

Dry separation
Eisenmann’s E-Cube is a widely successful and popular separator system. Thanks to its sophisticated filter technology, the E-Cube uses no chemicals, water or other additives (e.g. binding agents) whatsoever. This saves resources and simplifies waste disposal. The energy-efficient and resource-conserving E-Cube can be used in every phase of wet painting (i.e. for wheel, plastic and general metal painting). The system comprises 60 to 80 percent recycled materials, is easy to handle and can be operated by anyone.

Wet separation
Eisenmann offers two separation processes for wet erosion: compact cross-current Venturi scrubbers and double cross-current Venturi scrubbers. They can be used to treat different paint systems in a variety of volumes and adapted coagulations. In plants for automatic coating, most of the air which is suctioned out and scrubbed of paint mist is then fed back into the booth (recirculated-air operation). In oder to ensure that the permitted solvent concentration in the spray booth is not exceeded, a partial flow of the circulating air rate is released as exhaust air.

The paint drying process transforms a liquid or powder coating into a mechanically solid state. Eisenmann has built countless dryer systems, perfecting this process over the course of more than 60 years.

Convection dryers
Convection or air circulation drying is primarily used for paint curing. However, it’s also suitable for drying adhesives, gels and water. In addition, these dryers are also used to preheat parts prior to coating. Eisenmann dryers use targeted air flows to achieve optimum efficiency. The can also be split up into multiple heat-up and holding zones. Rapid heat-up and even temperature distribution can be individually adjusted to suit the workpiece geometry. The focus is on achieving fast processing times and high throughput rates while maintaining consistent quality.

Infrared dryers
In infrared radiation drying, the workpiece is heated up. The intensity of the radiation depends on the wavelength spectrum and thus on the radiation temperature. Temperatures of 3,000 degrees Celsius can be reached. Eisenmann’s infrared radiation dryers feature a compact design and extreme adaptability, allowing radiation to be used for a variety of different paints. Highly efficient, as well as direct and material-conserving applications result in energy-conserving and efficient processes.

Smart Oven
In the Smart Oven, clean gas is piped out of the dryer exhaust air cleaning system, indirectly heating the fresh air in the dryer. The combustion air for the burner is taken directly from the dryer, and the combustion gases are fed to the RTO exhaust purification system along with the dryer exhaust. This reduces gas consumption, especially since heat loss is kept low due to the low number of roof openings. The Smart Oven requires fewer attachments than similar concepts. The heating units integrated in the tunnel eliminate the need for costly steel structures. This dryer is more compact and lighter. The integrated heating system also reduces the overall surface. This results in less transmission heat and pressure loss.

Effective logistics concepts for the coating of metal and plastic parts are crucial to achieving optimum material flow and effectiveness in the overall plant. Complex, dynamic systems require detailed analyses. Our simulations can provide transparency and planning reliability and greatly assist with commissioning.

Skid conveyors
Lighter loads such as plastic parts undergo various processes on the skid conveyor. The precise guiding quality ensures optimum positioning accuracy and repeatability. This makes the skid conveyor particularly well-suited for use with robotic painting systems.

Power & Free
Thanks to their high flexibility with regard to speed and media, Power & Free systems can be used to combine a variety of production facilities and processes. This minimizes the number of workpiece transfers and system changeovers. This applies both to the Overhead Power & Free system and the Inverted Power & Free conveyor, capable of targeted workpiece infeed and pick-up, buffering, sorting and dosing. These systems can also be used for continuous workpiece conveyance. As a result, they allow for extremely energy-efficient, economical and flexible direct connection to upstream and downstream zones, as well as completely internal material flow.

VarioLoc
The highly flexible VarioLoc conveyor system transports plastic parts cost-effectively and without any skids. The integrated drive features variable speeds. This allows for dynamic travel at 0 to 120 meters per minute. The advantage is clear: The speed can be adjusted depending on the process step, and the workpiece travels through the entire paint shop on this VarioLoc. As a result, cycle times and throughput can be set and optimized flexibly.

Eisenmann has already been using the painting plant of the future for some time now and is an Industry 4.0 pioneer in surface treatment.

E-MES production management system
The award-winning Eisenmann Manufacturing Execution System, or E-MES for short, networks the factory, both horizontally, i.e. across the entire manufacturing process, and vertically, across all process levels - from the ERP to the PLC. With integrated data logging, analysis and display, it ensures thoroughly transparent production and logistics processes. E-MES can be variably implemented as anything from a simple operating and monitoring system to a complete MES solution. With its integrated data logging, analysis and display, it ensures thoroughly transparent production and logistics processes, forming the basis for every Industry 4.0 solution.

Virtual commissioning
And Eisenmann offers digital services throughout the entire value-added process. Automated software creation with E-PASS allows for virtual commissioning and intensive testing of the entire plant software in advance. This shortens the project execution time up to the start of production by up to 30 percent.

Digital services
All machines, functions and documents are managed through our service cloud. In conjunction with the service app, customers can request remote support and connect to an Eisenmann service technician. Communication occurs by scanning QR codes on the components or via smart glasses.

Contact

Name

Katharina  Baumann

Firm

Eisenmann Anlagenbau GmbH & Co. KG

Telephone

work T
+49 7031 78-1593

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