Category: Powder coating Line/plant/equipment’s

Symptoms Of A Bad Paint/Powder Drying Oven

How to know if your paint or powder curing oven is giving you issues? The paint curing oven is one of the most important part of your painting line and a bad curing oven can lead to a lot of risk and decreased productivity. Your curing oven should be able to satisfy all cure  parameters and perform consistently.

Some of the side effects or symptoms of  poorly designed paint curing oven are heat loss, chipping, poor airflow, orange peel, poor adhesion, difference in gloss, uneven colors/shade mismatching, poor chemical resistance, poor corrosion resistance etc. To avoid all these issues the paint curing oven must be designed properly with proper air flow and efficient heat exchangers (indirect heating). Prism ovens are well designed and known for their temperature accuracy. This is achieved through an effective air seal between the oven and the outside ambient conditions. Prism can supply various types of paint or powder curing ovens which include A Zone ovens, camel back ovens, ground mounted ovens and also IR ovens.

 

Things to Consider In An Extrusion Powder Coating Line

Installing a horizontal automatic powder coating plant/line can have its own set of challenges from an extruder point of view. As you know such investments should give your company a quick ROI and at the same time enhance your brand image. The plant should perform consistently satisfying all your demanding customers at-least for the next 20 years. Hence it is advisable to install a line with high quality standards with a professional design.

Many extrusion companies worldwide have made the mistakes in the past while choosing the wrong capacity and design of the plant looking at only plant manufacturers country of origin. But the architects and builders always demand quick deliveries, more colors, international quality standards etc. By spending marginally a higher price if you can have a plant with higher coating capacity, it will help you to drastically bring down the ROI period. We have all the calculations relevant for aluminium profile coating industry to support this claim.

Hence we strongly recommend you to focus on choosing the right type of plant design and coating capacity to bring down ROI period. Prism has installed numerous aluminium extrusion automatic powder coating lines around the world for many European and middle east companies around the world.

Over 100 Powder Coating Lines/Plants in UAE

Prism is proud to announce that UAE/Dubai as its second home as it has installed over 100 powder coating plants/lines in UAE region which includes Dubai, Abu Dhabhi, Fujirah, Sharjah, Rasal Kaimah etc. Majority of applications where our powder coating lines have been installed are for switch gears/panel boards, aluminium extrusions, fences, metal doors, transformers and many more.

We thank our customers from UAE for having their trust in Prism where they european quality at an Indian manufactured price.

Prism vs Other Paint Shop Suppliers around the world. Know the Difference

What makes us different is the question being asked time and again for the last 30 years by various customers around the world. Whether its a customer in Pune asking us what makes you different from other paint shop suppliers in Pune or a Delhi customer telling us that we already have so many paint shop suppliers in Delhi and why we must buy from you or the typical question we face from Europe, Italy or turkey is that why should we buy from India ?? Yes we have faced all these type of questions and today we are proud to announce we have installed 700 + lines/plants in over 25 countries.

Let us give you a glimpse as to how we are different and why should you consider us for a painting or a powder coating plant/line:

1) Prism is a 30+ year old company and has installed over 700+ plants worldwide for over 50 different types of applications which require different types of customization. With this our team is now capable of installing any time of painting or powder coating line for various types of industries/applications as the experience, technology , proven designs and plants running successfully over 15 years to 20 years has made our customers successful.
2) Prism is one among the few suppliers around the world which have 2 in house manufacturing units with quality control teams completely owned by Prism. This ensures fabrication quality, best construction methods, timely delivery and control over its manufacturing which leads overall performance and aesthetics of the plant.
3) All Prism Powder coating plants, Paint shops, Paint booths and Blast rooms are designed are expertly designed , engineered and manufactured with high quality steel, best brands of bought out components and each item is checked by our quality control team.
4) Prism front line team has a combined experience of 150 years of  project management, designing and installing Painting/ Powder coating plants worldwide. Our customers are guaranteed experienced individuals handling their projects.This is the trust our customers have on us.
5) With the acquisition of OMT Germany by Prism who has been the world leader in supplying complete powder and painting lines from Germany, you get proven designs, technology and the latest manufacturing methodologies from Germany. With this acquisition Prism offers its customers German engineering at Indian manufactured costs giving you cost advantage over other suppliers.
6) Our plants require very minimum maintenance compared to other suppliers and most of our installations run trouble free for over 15-20 years.
7) Our customers around the world can have access to Prism plants as we have a wide sales & service network.
8) Prism is one stop shop for all types of Painting lines. We offer complete powder coating lines , Painting lines , Paint spray booths, Drying curing ovens, Blast Rooms, CED coating lines , Shower tester booths, PTFE coating lines , Paint application equipment etc.

5 Advantages of Gas Catalytic Ovens

WHAT EXACTLY IS A GAS CATALYTIC/IR OVEN?

For curing any paint or powder coating one needs to heat the paint to a specific temperature and retain it for a certain period as recommended by the paint/powder supplier. It is assumed most of the ovens used worldwide will use convection heat transfer with airflow in the oven to heat the parts first which in turn will heat the paint/ powder. This means higher the thickness of the part longer the time it takes in the oven to cure the paint/powder. Consequently higher fuel consumption, high powder consumption, longer length of the oven etc. Normally powder/paint suppliers specify 10 minutes retention time at 180 degrees centigrade to cure powder and 25 minutes at 140-180 degrees to cure paint.
However if we use radiation heat transfer technique we will be able to heat paint/powder directly without heating the metal. However conventional electric infra red heaters produces intense short wave length which is highly sensitive when used to cure paint/powder. Further life of these electric heaters are limited which means replacement costs. Instead radiation heat can be created by oxidizing the gas
(LPG or Natural Gas) using a catalyst .The gas flow can be regulated using a digital program which can be varied or stopped zone wise. Combining little airflow with radiation can even cure paint/powder on complex shape parts. Typically these ovens cure powder in 3 to 4 minutes (total time) & 4 to 5 minutes to cure liquid paints on flat parts saving huge amount of fuel and power.

5 Advantages of using a gas catalytic oven in powder coating plants and painting lines/shops.

1. LOWER ENERGY CONSUMPTION

GAS CATALYTIC OVENS consume way less fuel (around 40 % – 60 %) THAN CONVECTION OVEN. The reason is in conventional ovens the complete component is heated so it consumes more energy and in gas catalytic covens only the paint/powder is heated without heating the whole component, hence gas catalytic ovens are energy efficient.

2. CURES METAL PARTS MUCH FASTER
In convention ovens the component is heated from room temperature to 200 degrees centigrade and it takes 10-12 min to cure depending on the size and thickness of the component. Further it has to be in the oven for a minimum period of time to ensure proper curing, due to this the length of the oven required will be a minimum of 24 meters.

3. MINIMUM MAINTENANCE COSTS

Gas catalytic ovens do not use burners and air circulation blowers hence bringing down maintenance costs drastically.

4.FLASH OFF ZONE NOT REQUIRED

Since gas catalytic ovens heat only the paint and not the whole surface, the time required to cool the component will come down.

5. LOW RUNNING COSTS

Gas catalytic ovens take up less space and consumes low energy hence bringing down running costs.

Prism gas catalytic/IR  ovens has been installed successfully and are running worldwide. This gas catalytic oven can be used to cure products like pressure cookers, rail coaches/wagons, hydraulic cylinders, bus bodies, shock absorbers, electric panels, fan components and many more.