INTO THE FUTURE
FORWARD 2020,
INDUSTRIALIZE YOUR BODY SHOP WITH SYMACH.
04
COMPANY
05
TECHNOLOGY
06
SPAP
07/8
FIXLINE
09/10
PRODUCTS
11
SERVICES
PRESENTATION 2014/15
4
OUR
COMPANY Symach was established in Bologna, Italy, in 2001 within the scope of a research project dedicated to fast paint drying methods. Since the very beginning, in fact, the company’s core business was car body shop. Symach holds numerous patents, including one for Drytronic technology, which allows for the drying of a clear lacquer in just 50 seconds. When combined with the SPAP process, in fact, Drytronic technology reduces application and sanding time by 60%. Since 2001, the company’s strategic research and development department has come up with a wide range of innovative car body shop products that allow us to offer comprehensive, unique and highly productive semi-automatic solutions, to the point that we are currently the only company that is capable of providing industrialized auto body repair processes. In addition to having sold over 2,000 drying Robots and developed over 50 complete body shops for large international groups to date, our systems are used by over 1,500 body shops on a daily basis. Symach offers the creation of complete body shops on an international level using the unique and innovative FixLine process, which provides for an average productivity increase of two repairs per week for each available technician, with an average completion rate of just 1.5 days from the date of acceptance. The company operates in full compliance with legal requirements: since 2003, in fact, the company has been awarded ISO 9002 Certification, and each robot is regularly certified in compliance with the CE, ATEX, IMQ and TUV SUD ISO 9001 standards.
5
Drytronic is a generator of different infrared wavelengths with an extremely bro-
DRYTRONIC
ad spectrum that employs an exothermic catalytic chemical reaction to combine
TECHNOLOGY
hydrogen and oxygen using natural gas or LPG. Since the catalytic chemical reaction takes place in the total absence of flames, there is no risk of fire or explosion, even if the panel were to accidentally come into contact with flammable liquids or gases. The Drytronic panel is therefore ATEX certified and approved for use in environments where explosive mixtures may be present, such as spray booths.
50” 100
SYMACH
DRYTRONIC SH ORT
IR ELECTRIC MEDIUM
IR ELECTRIC DIRECT-FIRED
SPRAY BOOTH
80
% OF DRYING
Drying times comparison
60
40
CONVENTIONAL
SPRAY BOOTH
20
0
04
06
12
16
20
24
28
32
36
40
MINUTES
Exothermic chemical reaction
The chemical reaction takes place because the catalyst inside the lamp breaks the gas molecule’s chemical bonds separating the hydrogen from the carbon. On the outer surface, the hydrogen coming out of the lamp is oxidized with oxygen thus creating flameless energy. And since there is no combustion, the carbon is released into the air in the form of carbon dioxide. The Drytronic generator emits a specific and selective spectrum of electromagnetic waves that release more than 85% of the energy contained inside the paint molecule. The patented Wave Length Control System (WLC) allows for the management of the various wavelengths based on the paint’s brand and type. SECTION LAMP NAT U R A L G AS Molecular Structure
Paint molecule
OXYGE N i n th e ai r
HI DR O GE N A ND OXYGE N
CATA LYST
chem i cal reacti on
The Drytronic wave spectrum penetrates directly into the paint molecule, instantly drying it: for example, it takes as little as fifty seconds of exposure to dry clear lacquer. The Drytronic unit can be used to dry various paints, materials and thicknesses, with almost no differences in terms of drying time and quality. The Drytronic lamp emits its radiation with a cone of fifty degrees, which significantly amplifies the exposure area and provides for two main benefits: a slower and more uniform increase in paint temperature, in order to prevent defects, as well as the proper drying of any particular angles or undercut curves. The Drytronic technology is entirely safe for human health, with absolutely no side effects resulting even from prolonged exposure. Furthermore, there are no risks posed to the eyes, since the radiation is in a wave spectrum that is entirely invisible to the human eye itself.
6
SPAP - Symach Paint Application Process - represents the proper painting
SPAP
method that integrates the use of both Drytronic technology and the robot. Since it dries the paint in just a few seconds, the Drytronic technology ena-
SYSTEM
bled us to develop a painting process that significantly reduces flash-off times, as the robot performs the process even faster. Drytronic drying quality - is superior to any other drying process involving the use of hot air ovens or electric infrared heaters, because reticulation is instantaneous and 100% complete. The painting product is chemically stable and inert. This prevents the appearance of any future defects, while at the same time allowing for immediate sanding and polishing. The SPAP application and drying process - is ideal for all painted products and for any brand name, even using different drying formulas, all while fully complying with the indications provided on the manufacturer’s technical data sheet. The time required to apply the paint to the products is reduced by 60% to 70%, while drying time is reduced by 80% to 90% with respect to any conventional system.
Filler - this application and drying process allows for filling operations to be completed with a single application, offering superior compactness and qua-
Filler
lity with respect to the application of two coats using the traditional cycle, in less than half the time. For example, the continuous and uninterrupted filler application and drying takes place in less than five minutes.
-5
Undercoat - the Undercoat application process is carried out without inter-
Undercoat
ruption, because the flash-off between coats is performed by the robot. For example, the application and drying of three coats of Undercoat can be performed in less than eight minutes. Drytronic technology even allows for the Undercoat to be applied using a
-8
roller, in thicknesses and with application and drying times identical to that of spray applications, but with a 60% savings in paint product and a 100% savings in terms of masking times and materials.
Water base - depending on the brand, the application of the two or three
Water base
coats takes place consecutively and without interruption. For example, less than six minutes are required for application and drying of three painted panels.
-6 Clear lacquer Clear lacquer - the application of two coats takes place consecutively and without interruption. For example, in order to paint three panels, less than
-12
twelve minutes are required for application and drying.
7
FIXLINE,
THE NEW BODY SHOP FORMULA
1
FixLine is the new modern body shop process that represents Symach’s latest concept in terms of productivity,
2
FixLine is a new layout and repair process which, when combined with Drytronic technology and the SPAP painting
quality and service.
cycle, provides for a 50% to 60% increase in productivity, as well as an increase of 1.5-2 repairs per week per technician: an objective that has already been achieved, and in some cases even exceeded, by many of our largest customers.
3
FixLine reduces vehicle movements between the various repair stages from 7 to 3, as various stages of repair activi-
4
Repair activities have changed considerably in recent years, with the majority of repairs shifting from larger and
ties themselves are carried out on the CarMover in the semi-automatic line.
more structure-related issues, to smaller issues of a more aesthetic nature. For this reason, we believe that the repair processes currently employed in the auto body repair industry are no longer suitable. Today, most body shops employ a single repair process, which, while certainly suitable for more extensive activities, in our opinion is poorly suited for activities involving the 1 to 3 panels that represent nearly 85% of total repair jobs. FixLine uses three different repair and layout processes, based on the number of panels to be repaired. In this manner, the system is capable of optimizing repair times and reducing labor costs by as much as four or five hours for each repair.
Our repair units are: Single-panel - single panel repairs, or more if cosmetic repair. These types of repairs make up 20% of the total market. FixLine repairs damage of this type in two hours, guaranteeing customer delivery in less than four hours. Standard - non-structural repairs involving two or three panels. These types of repairs make up 60% to 65% of the total market. FixLine repairs damage of this type in just less than eight hours, guaranteeing customer delivery in just one and a half days. Large - repairs involving four or more panels, including structural damage. These types of repairs make up 15% to 20% of the total market. FixLine reduces the current labor and delivery times by half.
8
5
Other advantages offered by FixLine.
Energy savings - With gas and electricity consumption of just 30% with respect to conventional drying systems, Drytronic technology offers a savings of up to 70%, with an energy cost of just a few cents per repair. Space - the system requires just half the shop space with respect to those employed in conventional body shops of similar size. A FixLine system of 800 sq. m is capable of performing fifty repairs per week. A FixLine system of 1300 sq. m is capable of performing one hundred repairs per week. Fewer vehicles in the body shop - since the repairs are carried out without interruptions, this allows each technician to work on a single vehicle, compared to the three technicians employed for conventional systems, thus resulting in a 60% reduction in necessary work space. Repeated repairs - The Drytronic drying system and SPAP cycle offer a 100% guarantee that every repair is final, with no risks of defects appearing after delivery to the customer. Advantages of the SPAP cycle - the SPAP cycle and Drytronic technology offer savings ranging from 25% to 30% on consumables. Drytronic drying technology allows for the application of the exact paint thicknesses, offering exceptional results in terms of coverage and shine. This eliminates the need to increase the thickness of the product in order to obtain optimal results respect to conventional methods. Polishing can even be performed immediately after drying, as the product is completely dry and stable. The SPAP cycle even simplifies the selection and the assortment of the paint lines to be used at the body shop, with a single catalyzer and clear lacquer to be used during all seasons and for all types of repairs.
WATCH THE VIDEO OF THE BODY SHOP FIXLINE 100 REPAIRS PER WEEK ON OUR YOUTUBE CHANNEL SYMACH Staff training - The FixLine process and the SPAP cycle simplify all repair stages, ensuring uniform and high-quality results superior to conventional systems, while at the same time facilitating and expediting staff training. Symach offers its customers several training courses, which are carried out by an expert team of painting and process technicians in order to ensure: The proper use of the SPAP work cycle The proper use of the FixLine process The proper use of all equipment A 30% increase in productivity is obtained after just two weeks of training. Body shop management - FixLine facilitates the management of the body shop in terms of daily and weekly repair scheduling, control of costs and productivity, and monitoring of quality and human resource.
9
SYMACH
PRODUCTS FLYDRY Flydry features a column supporting a 360° swivel arm lamp, moving in all directions, so that it can dry every side of the vehicle. The column and lamp unit movements are fully automated during the moving and drying phases. A laser temperature scan system always makes sure the treatment corresponds to the selected drying formula. A single Flydry can serve up to 4 preparation areas and 3 operators who can work continuously with no interruptions. An operator who works with a Flydry produces up to 3 times more.
ROBODRY Robodry is an automatic drying system for base and clear lacquer. The Shape Record Scanner System consists of a laser device that scans the vehicle or object to be dried with an idle run of the Robodry. It detects and stores the shape to allow the horizontal lamp unit to “navigate” around the object during the drying stage, always keeping a position parallel to the painted surface and at the correct distance. Robodry can perform a complete paint-and-dry job in half an hour and up 14 jobs a day.
EASYDRY Easydry can do a complete painting and drying job in just over half an hour and a painter can produce up to 12 works per day. Easydry features 3 laser sensors for dynamic temperature detection on each lamp unit and an LLS (Laser Level Shape) system that detects varying vehicle and/or object heights as the vehicle/object moves along during the drying process and sends the information to the computer. The LLS system automatically moves the horizontal lamp up and down between the up and down positions to adjust to vehicle height.
SPRAYTRON Spraytron can be used as a spray booth in combination with drying Robots, or as a traditional drying oven. SprayTron’s computer automatically recognizes the current operation by activating the fans at top speed during the paint-job, brings them to a lower speed during the drying phase and to an even lower speed while the operator is masking and preparing the vehicle for paint application.
10
SHOPLINE Shopline range includes a number of easy to install products, which are efficient because they include all required fixtures, cost-efficient and boast a cutting-edge design.
BASETRON Basetron, working area for vehicle repair jobs, is a suction basement for preparation of body filler and undercoat.
DRYBOX Drybox is an oven for drying detached parts such as bumpers, doors, hoods, hatchback doors, mirrors, wheel rims and other similar parts.
TINTOBOX Tintobox is a paint mixing room designed for paint products and related equipment.
CARMOVER Carmover is a system for quickly moving vehicles. It consists of four boards that travel on rails.
Request a catalog for all other products
11
OUR
SERVICES
Download our insights from this link: www.symach.com/details.asp
Symach operates in nearly every country worldwide, offering
Technical assistance - every country in which we operate is home
quality technical support and training services in relation to
to a technical assistance center that offers training for local techni-
the proper use of its equipment and the SPAP cycle.
cians, as well as spare parts kits for customers, which allow for all types of repairs to be performed in just in a few hours. Training - our technicians and training staff are highly experienced in the fields of painting and repair processes, and travel around the world to train our customers’ staff and managers for the proper use of the FixLine process and the SPAP cycle. Consulting and design - Symach employs experienced process engineers who are capable of designing operational processes and layouts for our customers’ body shops, offering consulting services and organizational and management advice for the establishment of a body shop or existing one.
FOLLOW US
Symach srl - Via Cassoletta, 41/A - Crespellano 40056 - Bologna - Italy www.symach.com - info@symach.com
Tel. +39 (0)51 963161