GRP Door slab manufacturer invests in their finishing future with Schuberts.

 

A significant, new, turn-key finishing installation has been commissioned at one of the UK’s leading GRP door slab, ancillaries and plastic components manufacturers.

 

 

 

 

 

 

 

 

 

 

The equipment comprises of a stand-alone horizontal automatic brush preparation machine. This through-feed machine uses Flex-Trim abrasive brushes to prepare the surface of the substrate. This then allows the slabs to be cleaned and then chemically prepared, ahead of coating. The through-feed brushing machine runs at 3m/min, meaning 380-400 sides can be processed per shift.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A load/unload automatic lifting station, when product up to 100kg each can be loaded and unloaded from the line with a single man.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The overhead conveyor is installed throughout the complete installation and with a max load on each 4 wheeled trolley of 200kg and a 90 degree sprung fitting for rotation.

 

Once loaded onto the line, a full ATEX rated spray enclosure with filtered air input and auto balance smart system has been installed for the spraying of the products. Individual silder divider panels are used to split up the spray zone into sector specific areas, allowing each of the potential 2 sprayers to spray at the same time.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Filtered air input, means all the incoming air for the spray process has airborne contamination removed, meaning no inclusions on the wet pieces being coated.

 

The inverter driven input and extract ATEX rated centrif fans are connected directly the PLC in the control panel and constantly alter their output depending on air pressures, filter condition and spray velocity required.

 

 

 

 

 

 

 

 

 

 

Once sprayed, the pieces go into a separate flash-off zone, where the coating is allowed to settle, vent and find its own level. Again, filtered air input means the wet product is kept clean and clear of particulate.

 

 

 

 

 

 

 

 

 

After the flash-off, a custom dimensioned Schubox is utilised for very rapid drying of the coatings. Running at just 36c, the gas catalytic IR heaters produce long wave infrared and along with a unique airflow inside the Schubox, the coatings are dried very quickly – around 45 minutes compared to 18 hours in ambient.

 

 

 

 

 

 

 

 

 

A dedicated ATEX rated paint mix room completes the installation. Bunded floor, ATEX heating, permanent extraction, filtered air, doors, work bench and ducting all feature in the PMR.

 

For more information on custom design manual and automatic spray finishing systems, email sales@schuberts.co.uk

 

 

 

Yorke Towne, Toronto, Test Centre Sees Additional Install

 

 

 

 

 

 

 

Yorke Towne Supplies Ltd, Schuberts’ sole agents for Ontario, Canada have just taken delivery of the next phase of the new production-spec Test Centre.

 

 

 

 

 

 

 

 

 

 

 

 

 

The fully integrated ATEX CSA system features a manual smart booth spray system. This constantly monitors and automatically adapts the airflow and pressure differential inside the spray zone, keeping dust out, vapours inside and overspray drawn into the extraction filters. The system makes up for doors being opened, quality and saturation of the filtration system and changes in factory pressures (dust extraction, loading bay doors etc)

 

 

 

 

 

 

 

 

 

 

 

 

A flash-off section connects directly to the spray enclosure and allows coated product to flow out, settle and vent before going into the Schubox for rapid drying. The flash-off features filtered air input and low level extraction, again with 1000 lux lighting sets.

The Schubox completes the Test Centre, allowing either solvent or water based coatings for wood, glass, PVC, GRP and composites to be rapidly dried, at low temperature in record time. Utilising CSA and ATEX approved gas catalytic log wave infra red emitters, the Schubox can run from 30c to 50c and in combination with BA stainless, fireproof carcass, filtered air input and a unique recirculating airflow inside the Schubox.

For more information and to run trials in the Yorke Towne Canadian Test Centre, email scesario@yorketowne.com or call +1 905-762-1200

WB Group Chooses New Schubert Finishing System For GRP and PVCu Products

 

 

From the company’s 70,000 sq ft factory in the north east of England, the WB Group fabricates and manufactures windows and doors in a large range of styles and finishes to suit every application.

 

WB Group was formed in 1981 and now has over 30 years experience in the manufacture and supply of PVCu windows and doors, GRP Composite Doors & PVCu door infill Panels.

 

 

 

 

 

 

 

 

 

Schuberts have just installed a brand new custom built finishing system for WB Group.

 

 

 

 

 

 

 

The system consists of a clean room spray enclosure, flash-off section, Schubox curing zone, overhead conveyor and paint mix room.

 

 

 

 

 

 

 

The spray enclosure pre-filters the air prior to entering the room. The balanced air system means the fans ramp up and down, constantly adjusting their output to suit all the variables of spraying. Doors open/closed, filters new/clogged all impact on the air balance inside a spray booth.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A flash-off area allows the coatings to settle, flow and vent prior to the Schubox. Again filtered air input ensures the wet product is kept clean.

 

 

 

 

 

 

 

After the flash-off, the Schubox gas catalytic IR drying system dries the 2k PU coatings in 30-40 minutes at just 36c with long wave infrared, air movement and reflection.

 

 

 

 

 

 

 

For more information about GRP and PVCu finishing systems, email sales@schuberts.co.uk

Big Is Beautiful!

Schuberts have just handed over the largest, highest capacity Schubox ever installed! This fully automatic turn-key curing system is feeding from a through-feed automatic spray machine and stacker.

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The Schubox installation is some 17m long end to end and 8m wide and features 2 individual processing lanes.

Two automatic inverted floor conveyors are specially designed to pull 8 trolleys of 500kg each at a set (adjustable) rate through the Schubox. That’s 8000kg of product being moved!

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Automatic doors on the infeed and outfeed mean the trolleys can be indexed through the system with minimal heat loss.

 

This gas catalytic technology is designed to cure 1000 microns (1mm!) of wet fire proof paint in a single pass in 90 minutes at 60c. There is no other system on the market that is able to process this film thickness in this time at such a low temperature.

 

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Each full trolley carries 22 wet panels and each lane in the Schubox holds 8 trolleys at a time inside. Based on a single shift and DOUBLE sided coating, this Schuberts installation is capable of processing 800 panels in a single shift!

 

The Schubox has instantly made a huge impact on production volumes and times. Previously, the coatings were taking 3 days to dry. Now just 90 minutes!

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It goes without saying, we’re very proud of this Schubox.

 

Email sales@schuberts.co.uk for more information on how we can reduce your surface coating drying times across industry.

 

 

#finishingsystems #schubox #drying #paintfinishing #automaticspray #automaticspraymachine #schubertsfinishing

Finishing Touch at Cardinal

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Cardinal have just taken delivery of a state-of-the-art Schubert finishing system for all of their joinery production.

The Cardinal Group has over 30 years experience in Designing, manufacturing and installing retail and commercial interiors in the UK and globally. The group operates from approximately 500,000 square feet of production and logistics space.  Cardinal provide a complete turnkey solution incorporating product design, space planning, manufacture, logistics, installation and project management.
Along with extensive manufacturing ability in the UK, Cardinal ltd also offer cost efficiencies via their China company and global supply chain.

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The new Schuberts system combines a fully enclosed 10m wide x 7m deep spray shop, filtered air input, adjustable divider panels and fully ATEX rated motors/fans etc for both solvent and water based range of coatings.

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A new control system on the spray shop means that all fans on the input side and extract side are inverter driven, ramp up and down automatically and maintain a perfectly clean spray zone, without any solvent vapour escaping into the factory.

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Custom fans and ducting was required due to roof heights, extended ducting lengths and the fact that the flap cowls had to finish some 5.5m above roof ridge height (!). Pulleys and belts were changed on the drives, ducting was flanged and increased to 810mm dia, oversized guy wires, extra strengthening to the roof was done – all to deal with the extra weights and loads of the ducting.

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The spray shop is illuminated with both roof and wall skywhite blue/white lighting sets. This gives a pure, flicker-free light, essential for colour matching and for the sprayer to spot imperfections inside the paint that can derive from the mixing process on 2k systems.

 

The Schubox drying system is manufactured to custom dimensions, specified by the client. 3850mm wide x 5480mm long, fitted with three flameless catalytic gas heaters. Drying time inside the Schubox is between 20 mins for high solids AC and one hour for high build 2k PU.

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A separate paint mix room was installed for the safe intermediate storage, weighing and mixing of coatings. A bunded floor catches all spills and twin doors allow easy access through into the spray shop directly.

 

To see how Schuberts can supply your own custom finishing system, email sales@schuberts.co.uk

 

#schubox #sprayshop #cardinalshopfitting #schubertsfinishingsystems

Schubert Pre-gel Oven Speeds Up Powder Coating Line

Schuberts have commissioned a new gas catalytic infrared pre-gel oven and overhead conveyor modifications for a large UK steel-work fabricator powder coating customer.

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The pre-gel oven uses high density gas catalytic IR to ramp up temperatures on the steel from ambient to 200c+ in less than 2 mins. This allows the production line to run twice as fast, the flame-gas hot air oven to run at 20% lower output and the overall finish far superior than previously.

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Schubert gas catalytic IR technology is an exothermic chemical process in which gas (natural gas, propane or butane) is converted into energy and long wave IR through precious metals such as platinum and palladium.

It is a totally flameless process using chemical conversion to catalyse the gas into the energy that is then emit in installations.

 

For more information, email sales@schuberts.co.uk