High Efficiency Vertical Powder Coating Systems
The two (2) World Leaders in Vertical Powder Coating technology have joined forces to provide the best vertical powder coating solution available. Tellkamp Systems, Inc. (Santa Fe Springs, California) and SAT S.p.A (Verona, Italy) have a combined reputation for excellence and continue to innovate and introduce new technologies to the vertical powder coating marketplace.
A key component of the vertical powder coating system is the pretreatment washer system. The Trevisan Tellkamp design uses an innovative cascade style washer to provide high performance pretreatment of the aluminum extrusions to meet the AAMA 2603, 2604 and 2605 specifications.
The cascade washer design eliminates the use of thousands of spray nozzles typically found inside the washer tunnel of a vertical coating line. The cascade system uses low maintenance trays to direct the flow of each pretreatment stage down over the top of the extrusions similar to a waterfall. Using the cascade system reduces the horsepower requirements of the washer, lowers the pretreatment chemical costs and saves water.
Trevisan Tellkamp offers two (2) vertical powder booth options. For high color change environments, a self-cleaning vertical powder both is available. The Self-Cleaning vertical powder booth automatically cleans itself at the touch of a button in less than 3 minutes. The vertical powder booth walls, floor and the ITW Gema automatic powder application equipment are cleaned without any involvement from the powder booth operator.
In production environments where color changes are less frequent, the standard Trevisan Tellkamp vertical powder coating booth is a good choice. The standard vertical powder booth design utilizes polyethylene booth sidewalls which are indexed downward for cleaning during the color change process. Complete color changes in the standard booth set-up can be performed by a single booth operator is less than 15 minutes.
Powder recovery and reclaim is accomplished using high efficiency cyclone technology allowing reclaim of high volume colors and spray to waste capabilities for short color run requirements. The high efficiency cyclone system can recover approximately 98% of the powder overspray and return it to the powder feed system for reuse.
The ITW Gema automatic powder application equipment is mounted horizontally on a full stroke reciprocator which results in tighter control of powder film build characteristics. The recipe based control system allows the operator to select a programmed set of powder coating parameters, assuring optimum application of the powder coatings.
The flexible design of the vertical powder coating booth allows the booths to be used either in series or in parallel operation to maximize production. Trevisan Tellkamp vertical powder coating systems utilize a unique overhead conveyor system that allows load bars of extrusions to move between powder coating cells for higher productivity and throughput while minimizing down time.
Each powder coating cell can contain one or two vertical powder coating booths complete with automatic powder application equipment and high efficiency powder recovery system. In parallel booth operation, powder coating both sides of the extrusion is easily accomplished using a single powder booth by rotating the extrusions 180 ° at the mid point of the vertical booth.
Operating in series, one or two powder coating booths can be used for production while the additional booth(s) in the second powder cell are cleaned during a color change. Series operation allows two vertical booths to be used at high speed to maximize the production capacity of the system.
Each powder coating cell contains one or two vertical powder coating booths complete with automatic powder application equipment and high efficiency powder recovery system. In series operation, powder coating of both sides of the extrusion is easily accomplished using a single powder booth by rotating the extrusions 180 ° at the mid point of the vertical booth.
After application of the powder coatings, the aluminum extrusions proceed to an indirectly heated convection oven for a complete cure of the powder coatings. The natural gas fired ovens are very energy efficient in design and provide the optimum environment to cure the powder coatings. Indirectly heating the powder cure oven eliminates the concerns about possible contaminants from the burner and helps provide excellent control over the temperature profile within the oven.