Things to Consider In An Extrusion Powder Coating Line

Installing a horizontal automatic powder coating plant/line can have its own set of challenges from an extruder point of view. As you know such investments should give your company a quick ROI and at the same time enhance your brand image. The plant should perform consistently satisfying all your demanding customers at-least for the next 20 years. Hence it is advisable to install a line with high quality standards with a professional design.

Many extrusion companies worldwide have made the mistakes in the past while choosing the wrong capacity and design of the plant looking at only plant manufacturers country of origin. But the architects and builders always demand quick deliveries, more colors, international quality standards etc. By spending marginally a higher price if you can have a plant with higher coating capacity, it will help you to drastically bring down the ROI period. We have all the calculations relevant for aluminium profile coating industry to support this claim.

Hence we strongly recommend you to focus on choosing the right type of plant design and coating capacity to bring down ROI period. Prism has installed numerous aluminium extrusion automatic powder coating lines around the world for many European and middle east companies around the world.

Over 100 Powder Coating Lines/Plants in UAE

Prism is proud to announce that UAE/Dubai as its second home as it has installed over 100 powder coating plants/lines in UAE region which includes Dubai, Abu Dhabhi, Fujirah, Sharjah, Rasal Kaimah etc. Majority of applications where our powder coating lines have been installed are for switch gears/panel boards, aluminium extrusions, fences, metal doors, transformers and many more.

We thank our customers from UAE for having their trust in Prism where they european quality at an Indian manufactured price.

5 Advantages of Gas Catalytic Ovens

WHAT EXACTLY IS A GAS CATALYTIC/IR OVEN?

For curing any paint or powder coating one needs to heat the paint to a specific temperature and retain it for a certain period as recommended by the paint/powder supplier. It is assumed most of the ovens used worldwide will use convection heat transfer with airflow in the oven to heat the parts first which in turn will heat the paint/ powder. This means higher the thickness of the part longer the time it takes in the oven to cure the paint/powder. Consequently higher fuel consumption, high powder consumption, longer length of the oven etc. Normally powder/paint suppliers specify 10 minutes retention time at 180 degrees centigrade to cure powder and 25 minutes at 140-180 degrees to cure paint.
However if we use radiation heat transfer technique we will be able to heat paint/powder directly without heating the metal. However conventional electric infra red heaters produces intense short wave length which is highly sensitive when used to cure paint/powder. Further life of these electric heaters are limited which means replacement costs. Instead radiation heat can be created by oxidizing the gas
(LPG or Natural Gas) using a catalyst .The gas flow can be regulated using a digital program which can be varied or stopped zone wise. Combining little airflow with radiation can even cure paint/powder on complex shape parts. Typically these ovens cure powder in 3 to 4 minutes (total time) & 4 to 5 minutes to cure liquid paints on flat parts saving huge amount of fuel and power.

5 Advantages of using a gas catalytic oven in powder coating plants and painting lines/shops.

1. LOWER ENERGY CONSUMPTION

GAS CATALYTIC OVENS consume way less fuel (around 40 % – 60 %) THAN CONVECTION OVEN. The reason is in conventional ovens the complete component is heated so it consumes more energy and in gas catalytic covens only the paint/powder is heated without heating the whole component, hence gas catalytic ovens are energy efficient.

2. CURES METAL PARTS MUCH FASTER
In convention ovens the component is heated from room temperature to 200 degrees centigrade and it takes 10-12 min to cure depending on the size and thickness of the component. Further it has to be in the oven for a minimum period of time to ensure proper curing, due to this the length of the oven required will be a minimum of 24 meters.

3. MINIMUM MAINTENANCE COSTS

Gas catalytic ovens do not use burners and air circulation blowers hence bringing down maintenance costs drastically.

4.FLASH OFF ZONE NOT REQUIRED

Since gas catalytic ovens heat only the paint and not the whole surface, the time required to cool the component will come down.

5. LOW RUNNING COSTS

Gas catalytic ovens take up less space and consumes low energy hence bringing down running costs.

Prism gas catalytic/IR  ovens has been installed successfully and are running worldwide. This gas catalytic oven can be used to cure products like pressure cookers, rail coaches/wagons, hydraulic cylinders, bus bodies, shock absorbers, electric panels, fan components and many more.