Dayline Advantage

Electrostatic powder spray equipment.

"DAYLINE" make the DPP 061powder spray equipment is assembly of spray gun, HV generator, powder hopper, control console and hose assembly. The unit is operated on230V, 50Hz domestic supply. Output voltage regulator is provided with rotary switch to give variable voltage from 40-90 KV DC negative at the tip of the spray gun. Powder hopper is provided with fluidizer tile separating the compressed air chamber from the powder chamber.

Control voltage for spray equipment is 18V DC for safe operations. Pressure gauges provided in control console to help control powder dilution with air. A micro ammeter displays the charging current continuously. Fuses, relay, 18V DC supply etc. are provided on relay card for ease in maintenance. Gun trigger controls relay card and air-flow control solenoid valve which in turn control HV generation & air flow.

Spray gun is designed light weight and ease in operation which have maximum flexibility. A specially designed cross wire electrode ensures maximum charging of powder particles so as to have maximum transfer efficiency of powder.

For the safety of the operator, 2 current limiting resistances of 50 M Ohm and 200 M Ohm are provided in HV circuit. Constant voltage gives a uniform coating on plain and intricate items. A spark free operation allows spray gun to coat intricate and sharp cornered objects uniformly and effectively.

Technical Specifications

Powder Output : Variable from 0-350 grams / minute

Output Voltage : Variable from 40-90 KV DC negative

Short Circuit Current : From 50-70 amps.

Max. Air Pressure : 5 Bar

Air Consumption : 10 cubic meter/hour

Input Supply : 230V, 50Hz, 1Phase, 100VA

weight : 750 grams

Safety Features : 200 and 50 MOhm resistors in HV circuit

Powder Spray Booth with recovery

The Spay Booth is the part of the system in which jobs are hanged over for powder spray. Main function of the spray booth is to provide clean atmosphere and to bar atmospheric influences on the job like wind, dust etc. It provides healthy and clean surrounding in powder coating area. Recovery system provides recovery of overspread powder with the help of cyclone formation in collection chamber so that the powder is collected in recovery bin and only clean air goes out to the air. Cyclone recovery system works so efficiently that it recovers almost 97% to 98% of the over sprayed powder.

Construction

Spray booth casing is made up to 16/18 swg steel with supporting structure having illumination, rotating device, control of air blower and a plug point for spray equipment. Recovery system is made out of 18 swg steel with removable body for cleaning. It is supplied with exhaust blower with motor, supporting structure and quick release bin. Connecting duct from spray booth to recovery cyclone is fixed at 1 end of spray booth with flanges, it is designed in such a way that powder does not stay in the duct. Bin is is also removable type for easy collecting and cleaning.

After assembly, exhaust blower sucks the air from front opening of spray booth where the over sprayed is mixed with the air, passes through the cyclone duct. The blower provides cyclonic action due to which heavier particles of the powder settle down in the bin and clean air moves out. Air velocity at the opening of the booth is maintained to facilitate optimum collection of powder. Whole system is designed for maximum safety of the operator.

Technical Specifications

Type : Fluidoline mini I/II

Recovery System : Cyclone Type

Air Exhaust : 4000/6000 CMH

Motor Capacity : 2/3 hp; 3000rpm; 3 phase; 50 Hz

Illumination : 40/60 watt tube light

Powder Curing Oven (Electrical)

Construction

The oven is made out of 16/18 swg steel in cassettes form. Oven structure is made out of 3 mm thick sheet steel formed in angle shape or 40x40x5 mm angles. The cassettes are made in double walled type construction filled with75 mm insulation of mineral wool or glass wool. These cassettes are provided with partitions so as to avoid any sagging of wool inside. Cassettes are then joined with angled frame to make a box type construction. Gap between them is further filled with insulation to avoid any leakages.

Spray booth casing is made up to 16/18 swg steel with supporting structure having illumination, rotating device, control of air blower and a plug point for spray equipment. Recovery system is made out of 18 swg steel with removable body for cleaning. It is supplied with exhaust blower with motor, supporting structure and quick release bin. Connecting duct from spray booth to recovery cyclone is fixed at 1 end of spray booth with flanges, it is designed in such a way that powder does not stay in the duct. Bin is is also removable type for easy collecting and cleaning.

Aft Statically and dynamically balanced blower is mounted on the top which recirculates the air in the oven thereby maintaining the temperature and avoids the formation of air pockets.

Technical Specifications

Insulation : 75 mm mineral/glass wool

Maximum Temperature : 200 degree C

Temperature control : By digital temperature controller

Trolley : One Nos.

Doors : Single/Double door each side

Powder/Paint curing oven ( HSD fired /LPG / CNG )

The ovens are basically either a box or tunnel type in construction. The 18 swg sheets of CRC are used in the construction of the oven. Frame of the oven is made out of 3 mm thick sheet steel which is formed in the shape of angles. The cassettes are made of steel in double walled construction with bent edges. To make it heat proof 100 mm glass/mineral wool insulation is provided and provisions are made so that the wool does not sag. The gap is then sealed with silicon adhesive sealants so that there is no escape of heat. To provide energy to the oven we use HSD/LDO burner. The burner is mounted on a heat exchanger with asbestos mounting to make it leak proof. A heat exchanger constituting firing chamber and tubes is provided for better transmission of heat throughout the oven and it's longer life. Fuel gases exhaust point is also provided in heat exchanger so that waste gases are exhausted through the chimney. Heat exchanger is mounted on rails so that it can be easily cleaned and maintained. A suitable designed oil filter is also provided in the input line of HSD oil burner to avoid any impurity to the burner.

Technical Specifications

Heat Exchanger : SS304 Complete

Burner make : Ecoflame/FBR/Bentone/Lombargini/Equivalent

Burner : 1/2 Nozzle

Temperature : 220 degree C

Temperature Control : Digital Control

Air Circulation : By Central Blower

Blower motor : 3/5/10, 3 horse power, 50 Hz

Insulation : 100 mm glass/mineral wool

Doors : Single/double each side

Trolleys : 1 Nos.

Powder/Paint curing oven ( HSD fired /LPG / CNG )

The ovens are basically either a box or tunnel type in construction. The 18 swg sheets of CRC are used in the construction of the oven. Frame of the oven is made out of 3 mm thick sheet steel which is formed in the shape of angles. The cassettes are made of steel in double walled construction with bent edges. To make it heat proof 100 mm glass/mineral wool insulation is provided and provisions are made so that the wool does not sag. The gap is then sealed with silicon adhesive sealants so that there is no escape of heat. To provide energy to the oven we use HSD/LDO burner. The burner is mounted on a heat exchanger with asbestos mounting to make it leak proof. A heat exchanger constituting firing chamber and tubes is provided for better transmission of heat throughout the oven and it's longer life. Fuel gases exhaust point is also provided in heat exchanger so that waste gases are exhausted through the chimney. Heat exchanger is mounted on rails so that it can be easily cleaned and maintained. A suitable designed oil filter is also provided in the input line of HSD oil burner to avoid any impurity to the burner.

Technical Specifications

Heat Exchanger : SS304 Complete

Burner make : Ecoflame/FBR/Bentone/Lombargini/Equivalent

Burner : 1/2 Nozzle

Temperature : 220 degree C

Temperature Control : Digital Control

Air Circulation : By Central Blower

Blower motor : 3/5/10, 3 horse power, 50 Hz

Insulation : 100 mm glass/mineral wool

Doors : Single/double each side

Trolleys : 1 Nos.

Conveyorized Systems

Before considering the design and implementation of a conveyorized powder coating system, a few questions need to be answered. Proper design begins with preparation and research.

Where will the system be built?

Location is essential for efficient transportation of products to and from the powder facility.

What is the available floor space?

As you begin designing the powder application system, it's important to have a clear understanding of the facilities floor space and the location of each of your utility hook-ups. It can be very costly to find that you placed your pretreatment area on the wrong side of the building, away from drainage and water hook-ups.

What size is the largest part that will move through the application system.?

Length, width, height and weight are considerations.

What kind of production rates are necessary?

Consider short and long term requirements.

What utility capacities are available?

Electrical, water, gas and air; and drainage lines.

What permits are required?

Building permits for modifications, air quality requirements, fire protection, sanitation.

These requirements may be different in each location. And, this listing is not meant to be complete. You need to do your homework. Proper research saves time and money.

The conveyorized system is for higher production needs and generally begins with a loading station for the loading of jobs onto a properly grounded conveyor and racking system. A conveyor to transport jobs from one station to the next is essential. The importance of cleaning and proper lubrication of the conveyor cannot be over emphasized.

The conveyor transports the parts into the pretreatment system which generally consists of a three or five stage spray washer, most often iron or zinc phosphate. The washer includes rinse stations that use fresh, recycled and/or deionized or filtered water.

With the phosphate spray washer, your chief concerns are:

The control of time, allowing the various stages to perform their desired functions.

The control of temperature, enhancing cleaning and phosphating.

The control of chemical concentration, the amount of chemical in solution is measured by titration, allowing the cleaning and phosphating baths to be monitored and adjusted.

The control on nozzle pressure, relating to impingement properties and the physical removal of soils and surface contaminates.

Proper line speed and constant monitoring of all control variables will ensure a clean, uniform surface. Also accurate maintenance and record logs are necessary to keep your operation running smoothly and efficiently.

As the parts leave the pretreatment area they are wet from rinsing and must be dried. Forced drying takes place in a separate dry-off oven, or a section of the cure oven. Using the cure oven reduces the system's size and eliminates the need for another burner and controls.

After the parts are pretreated and dried they are generally allowed to cool to, at or near ambient temperature. The parts then enter the powder application booth, complete with collection and/or powder recovery equipment. The powder application booth serves as a containment system for over-sprayed powder. This powder material can be collected for reuse or discarded as scrap, oven. The parts are exposed to heat inside the cure oven for the proper length of time and with the correct atmospheric temperature setting to allow the coating to bond with the substrate according to the powder manufacturer's cure recommendations.

Finally, there needs to be adequate time to allow parts to cool for off-loading and packaging. With careful planning and proper research, the odds will be stacked in your favor in the design of an efficient and profitable powder application system.