ipcm® n. 57 - May/June 2019

Page 49

FOCUS ON TECHNOLOGY

providing development and strategy

efforts in this area for some time when, in

system soon made it clear that this

support to customers from practically

the spring of 2015, he asked his son Timm

project would require significant

every business sector, today H.P. Kaysser

to be responsible for the planning and

investment and the construction of two

offers intelligent, economical solutions

construction of a new coating system. “We

brand new production halls.

that range from engineering services

were looking for the right combination of

For the planning and configuration of

and the full sheet metal processing chain

the highest quality coating, in an optimal

the coating technology, Kaysser drew

right through to logistics. With some

process,” recalls Timm Kaysser. “Firstly,

on the extensive experience of

30,000 m² of facilities, the company’s

we needed the best ingredients for the

CS Oberflächentechnik, a company that

fully automated operations fabricate and

identification and coding of workpieces

had already participated in the creation

process products made of steel, cast iron,

throughout the transport, pre-treatment,

of several major powder coating lines.

stainless steel and non-ferrous metals

masking and coating operations. But we

The first new production hall was

– as individual units or in small, medium

also needed an intelligent control system

completed at the end of 2018

or large batch sizes. Customers take

to link everything together.”

in the first phase of the project.

advantage of their high quality, low prices

A second construction phase slated for

and rapid lead time, with the company

completion by the end of 2020 is still

experiencing steady growth. H.P. Kaysser have always excelled in surface finishing and even in their early history they focused on alternatives to liquid coating systems. When H.P. Kaysser installed their first powder coating plant in 1969, this new technology had only just been launched on the market, and their plant was one of the first and biggest in Germany. The vintage system was still fully functional and in daily service until recently, working alongside a second unit, installed in 1989 to automatically process larger workpieces. Over the past 30 years, coating

underway. With 2,800 m² of floorspace,

Over the past 30 years, coating operations and associated processes such as colour change and system cleaning have achieved such a high level of automation that modern powder coating lines are essentially when it comes to meeting the demands of “smart factory”: maximum flexibility for the economical production of even small and extremely small series right down to batch size 1.”

operations and associated processes

the first hall houses a powder coating line that handles components up to 2.5 x 1.0 x 1.5 m in size and 350 kg per carrier, in series and with eight scheduled colour changes per day. Workpieces first pass through a pre-treatment area comprising of up to six zones and incorporating numerous buffer and sorting storage options for maximum flexibility on their way to the heart of the powder coating plant: a state-ofthe-art coating booth from Nordson, designed for both maximum colour change speed and extreme cleanliness.

such as colour change and system

Based on a ColorMax3 booth, a variant

cleaning have achieved such a high level

Accordingly, the plant specifications stated

was adapted to the existing space

of automation that modern powder

the following requirements:

constraints, which is why the

coating lines are essentially when it

– Secure investment in long-term, future-

2.6-meter-long foreshortened booth

comes to meeting the demands of

proof technology

with a lower roof as installed at

“smart factory”: maximum flexibility for

– Extremely high flexibility in production

H.P. Kaysser is designated as a

the economical production of even small

– Minimized environmental impact and

ColorMaxE (“Engineered”).

and extremely small series right down to “batch size 1”.

Sustaining growth, enhancing flexibility The modernization and improvement of powder coating capabilities to meet

maximized sustainability – Creation of capacity to coat all in-house

The high-strength, exceptionally smooth surfaces of the booth components

production in the company’s own coating

ensure minimal powder-in-process at

system, irrespective of the size and

all times and perfect illumination in the

weight of the components

booth, facilitating easy visual quality

– Creation of additional capacity to cover subcontract work as a job coater.

inspections. During operation, the intelligent airflow management system provides regular

current and future requirements were nothing new to Thomas Kaysser, CEO of

The size of the components to be

compressed air pulses to convey

H.P. Kaysser and son of the company’s

coated and the resulting dimensional

excess powder to the central channel

founder. He had already been focusing

requirements for the powder coating

extraction system, which effortlessly

international PAINT&COATING magazine - MAY/JUNE 2019 - N. 57

41


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ipcm® n. 57 - May/June 2019 by ipcm® International Paint&Coating Magazine - Issuu