EISENMANN

Powder Coating
 EISENMANN is among the
leading worldwide manufact-
urers of complete coating
lines. We work with the most
advanced technologies and
experience gained over the
decades from several hundred
real-world paint lines.
EISENMANN is the expert
partner for future-oriented
surface technology in all areas
of industrial coating, from job
coaters to the automobile
industry.
Working in small teams, our
engineers collaborate with
specialists in environmental
engineering, conveyance tech-
nology, and control technology
to develop individual system
designs.
We demonstrate our competen-
ce in more than just equipment
design. As operators of comp-
lete painting facilities for the
auto industry, we are respons-
ible through our own personnel
for economic facility operation
and the highest surface quality.

Contents

Advantages of Powder Coating 1

Powder Coating Lines

from a Single Source 2
Glass Powder Booths 4

Powder Booths with

Filter Recovery 5

Booths with Cyclone

Separation 6
Changing Colors 7
Cleaning and Pretreatment 8
Material Flow Automation 9
Powder Curing Ovens 10
Real-World Examples 11
Service and Maintenance 12

Continuously providing new designs, EISENMANN

is the trend-setter in surface technology.
Example: the glass booth(above) or powder lines
for the automobile industry.
 EISENMANN Technology and Know-how:
EISENMANN Powder Coating Systems.

Convincing Advantages > Easy to automate. Color Selection no

The advantages of powder
coating compared to other
coating processes are convin-
cing:
> Virtually loss-free coating by
means of overspray recovery.
> High-quality coating with an
extremely scratch-resistant,
shock-resistant, and
corrosion resistant surface.
> No exhaust air problems,
no paint sludge.
> Coating thickness of Problem
40 to 200 m (1.5 to 8 mils)
are possible in one coating. Advanced powder booth and
custom system designs make
Over time, companies of all possible economic operations
sizes and from all fields have and a high degree of flexibility
made good use of these advant- even for users who change
ages. Now the auto industry - colors frequently. EISENMANN
trendsetter in terms of quality, has the right system for every
economy, and environmental use: powder booth with filter
compatibility - has also joined recovery, cyclone separation,
the ranks of those using or combined systems for both
powder applications with methods.
equipment from EISENMANN.

The first ever overhead powder top coat line for the the automobile industry from EISENMANN.
1
Advantages from Custom Solutions:
The Complete Powder Coating Line from a Single Source.

Perfect Fit
Turnkey - all equipment
components in perfect harmony
with each other - that’s your
new powder coating line from
EISENMANN:

Water-saving pretreatment,
powder booth made of glass or
stainless steel, energy-saving
ovens, efficient material flow
systems, and advanced con-
trols. EISENMANN has its own
in-house experts for all of
these areas of concern. So
you only need a single party
to answer all your questions
regarding the implementation
of your new powder line.

Today’s coating lines are integrated

in the production flow, reduce emiss-
ions and wastewater. Together with
EISENMANN, this manufacturer of
mailbox systems in the photograph
on the left has implemented state-of
the art coating facilities at various
locations.

EISENMANN delivers automatic and manually-

operated powder booths for all application systems..

2
In order to obtain first-class surface
quality, the workpieces must undergo
a perfect pretreatment which is
specifically laid out for your parts.

Fancy controls for appliances

(above): All process parameters
can be displayed and altered on the
viewing screen on the control panel.
Diagnostics can be conducted in the
same manner.

Flexible material flow systems,

like EISENMANN’s Power & Free
Conveyor, organize the production
flow and connect the coating
process to the production processes
both upstream and downstream.
3
Transparent in Every Respect:
Powder Booths Made of Glass.

Transparent in every respect:

EISENMANN has created powder
booths made of glass. Special
safety glass and walk-on
stain-less type steel floors
have proven their value in
real-world operations.

The Advantages
of Glass Booths
> Less powder adhesion than
in conventional booths
because the booth walls
cannot be electrostatically
charged.
> Super-smooth surface, very
good for cleaning.
> The ideal workspace for the
manual coater. The transpa-
rent booth is easy to see
into and permits personnel
to have visual contact with
the work environment.
Because of the well balanced
electrostatic conditions, the
powder cloud goes directly
onto the workpiece (instead
of onto the coater).
Clean Floor,
Best Surface Quality
Best coating quality is
achieved when there is little
powder in circulation.

This is why an automatic floor

sweeping system is integrated
into EISENMANN powder
booths; it conveys overspray
powder, that has not reached
the recovery system, into the
reservoir.

This is how the floor sweeping

system, in conjunction with
the powder recovery system,
forwards all of the overspray
immediately back into the
powder circulation system.

4
 Clean Air without Losing Powder:
Powder Recovery with Filter Systems.

Powder booths with filter The Advantages

recovery have proven them-
Conveyor
selves in the most strenuous Plastic Filter: Powder booth
real-world conditions. Highest degree of separation, Housing unit made of glass or
stainless steel
high mechanical stability, with filter
blow-off unit
Powder booth, recovery, and easy to clean. Reciprocator
filters form a unit in which Better Air Flow: with guns

the complete recovery system Horizontal powder cloud with

can be exchanged depending better wrap-around. Powder filter
made of
on the color desired. The filter Short Powder Paths: sintered plastic
is cleaned automatically during Reservoir is directly below
ongoing operations, the exhaust the filter!
Rapid Color Change: Inspection
air is returned directly to the hatch
hall as circulating air. Detachable recovery units, Powder
movable powder booths or sieve
automatic filter cleaning Refill
opening
system.
Easy Operation: EISENMANN
All units requiring maintenance
are accessible and controllable
Powder reservoir Fluidized bed
This manufacturer of radiators uses during operation (i.e., sieve
the glass booth with performance machines, reservoirs, etc.).
plastic filter..

5
For Many Colors and Small Series:
Powder Recovery with Cyclone Separation.

Powder booths with cyclone

separation (mono- and multiple-
Conveyor
cyclones) are ideal for distinct
Powder booth made movable
of glass or stainless many-color coaters. In general,
multiple
steel cyclone the cleaning of the separator
to
Reciprocator absolute system in cyclone booths is
with guns filter simpler than in filter booths,
although the powder loss is
higher.

The exhaust air travels horizon-

tally through side openings into
the cyclone. The recovered
powder is transferred through
a conveyor and a sieve into the
main reservoir.

EISENMANN

Vibrator for Sieve machine

powder container This manufacturer coats aluminum
profiles and facades in many special
colors in an EISENMANN powder
booth with a mono-cyclone.

Intermediate powder container

for conveying powder over long
distances for high powder through-
put.

6

The following criteria are
important in terms of good
color changing concepts:
> Frequency of color change
and production time per
color.
> Percentile distribution of
colors to be processed.
> Number of colors to be
processed.
> Capacity and utilization
of the system.
Shown in the diagram: designs
for rapid and economic color
changes with two or more
movable powder booths with
filter recovery systems.
From Black to White:
Implementing Colors Changes.
When throughput is not very
high and the color is only
changed every few days, a
single additional recovery
unit generally suffices.
Frequently several movable
powder booths are used
when there are high levels
of throughput with standard
colors and additional special
colors.
When a booth is off-line, the
color is changed by exchanging
the complete recovery unit or
by cleaning the filter in the
special automatic cleaning
system. Booths with cyclones
have proved worthwhile for
very frequent color changes
with small production runs.
The right fit in color change
design is a requirement for efficient
operations for job coaters with
frequent color changes. EISENMANN
Diagram below: High rates of
offers individual solutions with
throughput and many colors require
its movable powder booths and
several partial powder lines that
different recovery systems.
have different recovery systems.
Powder line 1 Powder line 2 Powder line 3
Standard colors Standard colors Special colors
Booth 1
Booth 2 Filter booth 1 Filter booth 2 Cyclone chamber
7
High Quality and Practical Environmental Protection:
Cleaning and Pretreatment.

EISENMANN’s advanced pre-

treatment equipment saves
fresh water and wastewater, is
environmentally friendly, and
ensures the greatest surface
quality.

Maintaining and extending the

life of process and rinse baths
is not just economical, but it
also makes environmental
sense.

So today rinse water is used

multiple times using counter-
flow or recycling techniques.
Life for cleaner baths can be
increased substantially by
dividing into multiple zones
or by using continuous oil
separators.

Further standardized concepts

are available for extending the
service life and are optimally
selected by EISENMANN in
accordance with the applicat-
ion in question.

When the throughput is not all

that high, a wastewater-free
pretreatment utilizing an
evaporator is an interesting
alternative. No water goes to
the drain; any distillate flows Spray pretreatment with numerous options for bath maintenance.
immediately back into the
system.
Degreasing I Degreasing II
Rinsing I Rinsing II DI rinsing

Schematic of effluent-free pretreatment.

8

Material Flow Automation at the Highest Level.
EISENMANN develops in-house
the complete material flow
and control technology for
automatic coating lines.
We work out the best solution
for you individually in terms
of efficient production flow,
greatest operational reliability,
and highest degree of economy.
Everything in Motion:
Overhead conveyors, Power&
Free conveyors, skid conveyors,
programmed hoist systems, lift
stations, transfer mechanisms
and specifically developed
special conveyors are fine-
tuned to the workpieces and
the operation.
Handling devices or gantry
robots are available for
connecting different conveyor
systems and for workpiece
loading and unloading.
Ideal in coating and painting
operations are destination
controlled, flexible and robust
Power & Free systems.
Gantry robots connect different
conveyor systems in a wheel
coating operation. The robot
transfers the just-powdered wheels
from the spindle conveyor to the
chain-on-edge conveyor of the
powder curing oven.
9
Economical and Energy-Saving:
Powder Ovens, Any Style.

EISENMANN curing ovens are

designed for high efficiency
and the best surface quality.
Continuous ovens with single
or multiple passes or block
arrangements with the water
dry-off oven are heated direct-
ly or indirectly with oil, gas,
electricity or recovered energy.

The structures range from

floor-mounted single chamber
ovens to elevated multiple
pass ovens with energy-saving
bottom entry/exit and optimi-
zed heating designs.

There are infrared ovens for

workpieces with temperature
sensitive components or high
material thicknesses. Infrared
ovens are also frequently
employed as pregel zones for
conventional convection ovens
because of their excellent
cross-linking effect on powder.

Melting phase with IRM

emitters Powder oven
Circulating air duct

Circulating air duct

Circulating air duct

Circulating air duct

Circulating air duct

Circulating air duct

Water drier

Combined water drier and powder oven with IRM emitters and air recirculation for aluminum wheels.

10

This company offers its customers lighting systems in a great variety of
colors. Using the new EISENMANN powder line, it is economical to process
standard colors in large lot sizes and special colors in small batches.
The first European plant for EC priming and powder coating of fully welded
truck chassis was planned and built by EISENMANN. After electro-coating,
the workpieces weighing up to 6 tons each are top coated in one of the
three powder coating booths.
Four Possibilities, out of a Hundred:
Real-World Examples.
Heaters are increasingly delivered in fashionable colors. With two automatic
booths for standard colors, 1 automatic booth having 6 recovery units for
special colors, and one manual booth for small production runs and indivi-
dual pieces, this manufacturer has ensured his competitiveness far into the
future.
Complete powder coating plant with Power&Free system for compressor
housings.
11
Service and Maintenance
The EISENMANN Service offers
an extensive range of services.
These are tailored individually
to the customer's needs, there-
by taking the know-how of the
customer's employees, the cost
structure, the processes and
the need for expertise into
consideration.
Therefore, we regard ourselves
as system providers when it
comes to meeting the individ-
ual customer's requirements.
Maintenance Management
• Inspection
We determine the actual state
of your system by conducting
inspections and then inform
you about the weak spots and
possibilities for increasing your
performance, or let you know if
there is an urgent need to take
action.
• Servicing
In order to determine the tar-
get state of your system, our
specialists not only conduct
the servicing, but also carry
out mechanical and electrical
check-ups and safety tests.
Routine servicing guarantees
an optimum functioning of
your system and increases its
service life.
• Repair
Our maintenance team also
carries out any necessary
repairs and component replace-
ments of course.
• Remote System Diagnosis
Using remote data communic-
ation, the remote system diag-
nosis enables our specialists
to access your controls and
material-flow computers quick-
ly and easily, and remedy any
faults within the shortest time.
12
On-call Service
We offer you a 24/7, on-call
service conducted by our
Service specialists, which is
based on a mutually agreed
response time and customised
to your own specific shift
operation and production
times.
Service Contracts
• Maintenance Contracts
You can rely on EISENMANN
Service. We offer you custo-
mised Maintenance Contracts
for your system. You are
reminded in good time of
the next routine service which
is carried out by qualified
engineers. This enables you
to plan the costs on a contin-
uous basis and reduce the
system downtimes by taking
preventative measures.
• Full Service
Due to our excellent experi-
ence gained in the construc-
tion and operation of highly
automated industrial systems
and factories, we are able to
take over the entire mainte-
nance of your system, allowing
you to fully concentrate on
the key processes of your
business. We guarantee system
availability at all times, and
the value of your systems is
preserved long-term through:
• Preventative maintenance
• Troubleshooting
• Repairs
• System Reconstructions
The EISENMANN Service is your
first contact for system recon-
structions or extensions,
whether for paint-spraying and
environmental technology, or
for process technology and
materials handling. We adapt
your systems engineering to
new conditions if, for example,
you should wish to increase
your throughput, or the
product dimensions or weights
have changed, or if your space
planning necessitates this.
We likewise offer you a first
class service where production
relocation is concerned.
• Updates
Modernisation or conversions
to new systems require modifi-
cation measures, such as
replacing controls, software
and hardware updates, for
example. Our specialists, with
their high level of expertise,
are available at all times.
Process Optimisation
We also offer you advice,
of course, when it comes to
opti-mising your production or
improving it on a continuous
basis. We place application
and process specialists at your
disposal who thoroughly ana-
lyse your processes and find
out where the weak spots are.
In close liaison with your
employees targets and mea-
sures for optimisation and
plans of action are defined.
Key issues can, for example,
include quality problems, cost-
saving potential and prevent-
ative maintenance concepts.
Run-up Support
With its “standby” concept
EISENMANN offers individual
support on site. Excellently
qualified EISENMANN staff
support your personnel by
accompanying the production
at start-up and also during the
production. Your personnel are
not left to their own devices
here; they have direct access
during the operations to the
“standby” staff who step in
when the situation becomes
critical.
EISENMANN
www.eisenmann.com
EISENMANN Anlagenbau GmbH & Co.KG
Tuebinger Strasse 81
71032 Boeblingen . Germany
Daimlerstrasse 5
71088 Holzgerlingen . Germany
Phone +49 7031 78-0
Fax +49 7031 78-1000
info@eisenmann.com
EISENMANN Service GmbH & Co.KG
Tuebinger Strasse 81
71032 Boeblingen . Germany
Phone +49 7031 78-3000 (6.30 - 18.30 h)
Fax +49 7031 78-3200
info@eisenmann.com
EISENMANN Ingeniería S.A.
Parc de Negocis Mas Blau
Edificio Prima Muntadas
c/Berguedà, 1 . Barcelona
08820 El Prat de Llobregat
Phone +34 93 479-6610
Fax +34 93 479-6620
info.spain@eisenmann.com
EISENMANN France S.a.r.l.
Espace Lumière . 2, Rue Pathé
78406 Chatou Cedex
Phone +33 1 30159800
Fax +33 1 30531009
info.paris@eisenmann.com
EISENMANN Italia S.r.l.
Via Ferrari, 21
21047 Saronno (VA)
Phone +39 02 96718-626
Fax +39 02 96718-629
info.italia@eisenmann.com
EISENMANN U.K. Ltd.
Unit 118 Severn House
Anson Court Business Centre
Staffordshire Technology Park
Beaconside . Stafford
Staffordshire ST18 OGB
Phone +44 1785 283790
Fax +44 1785 283799
info.uk@eisenmann.com
EISENMANN Corporation
150 East Dartmoor Drive
Crystal Lake . Illinois 60014 . USA
Phone +1 815 4554100
Fax +1 815 4551018
info@eisenmann.com
EISENMANN do Brasil
Avenida Duquesa de Goiás, 716
3° andar . Bairro Real Parque
CEP: 05686-002 São Paulo SP
Phone +55 11 21611200
Fax +55 11 37580030
info.brasil@eisenmann.com.br
EISENMANN S.A. DE C.V. Mexico
Blvd. 15 de Mayo 2933
Fracc. Las Hadas
72070 Puebla, Pue.
Phone +52 222 2311712
Fax +52 222 2498835
info.mexico@eisenmann.com
EISENMANN Shanghai Co. Ltd.
Room 301, Gubei Intern. Fortune Center
No. 1452, Hong Qiao Road
Changning District
Shanghai 200336 . P.R. China
Phone +86 21 31352188
Fax +86 21 31352199
info@eisenmann.sh.cn
OOO EISENMANN
Ul. Pyatnitskaya 47-1
119017 Moscow
Russian Federation
Phone +7 495 951-6824
Fax +7 495 951-5211
info.russia@eisenmann.com
EISENMANN India Pvt. Ltd.
EISENMANN Surface Finishing Systems
India Pvt. Ltd.
Technosoft Knowledge Gateway · 1st Floor
Plot No. B-14 . Road No. 1
Wagle Industrial Estate
Thane (W) 400 604 Maharashtra . India
Phone + 91 22 2583 2929
Fax + 91 22 2583 3800
info.india@eisenmann.com