Composite Door Manufacture Installs Second Schubert Finishing System

The UK’s fastest growing and probably best-know producer of composite GRP doors has taken delivery of a second turn-key bespoke finishing system from Schuberts.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The line incorporates an overhead conveyor track, spray shop clean room with filtered air input and extract, flash-off zone and Schubox drying technology.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Once prepped and cleaned, the doors are hung onto the conveyor and moved into the spray shop for coating. Both the air input and extraction are inverter driven, giving a balanced air flow irrespective of the condition of the filters. The sensors fitted to the spray shop will even tell the operators when to change the filters.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The flash-off section allows the coating to flow and settle before going into the catalytic IR zone for rapid drying in about 45 minutes.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Once dried, the products are taken off the line and moved into the rest of the factory production system.

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

 

 

 

Giardina Profile Coating Line Installed At Timber Door Producer

A new Giardina profile finishing line has been installed by Schuberts at a well known timber and PVC fabricator.

 

 

 

 

 

 

 

 

 

 

The line consists of infeed conveyor, brush-sanding machine, profile spray machine, automatic stacking system and drying trolleys.

 

Timber, anything up to 300mm width x 4000mm length can be fed down the profile line by hand, thereafter it is fully automatic.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The multi-headed brush sanding machine is fitted with Flex-trim heads to give an optimal pre-sand and intercoat denibbing. All heads on the sanding machine can be angled, rpm altered and direction of rotation changed, all depending on the substrate and quality required.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The Giardina profile spray machine features double fluid lines, filtered air input and extraction, collection tanks for overspray and 4 automatic spray guns. As the product passes into the spray machine, the piece is ‘read’ and the guns actuate on and off automatically, giving an even and regular coat of paint.

 

Once coated, the product is then transferred to the stacking system, where the wet profiles are taken and loaded into each arm of a drying rack. This is done fully automatically from top to bottom, with random length and width pieces being no issue for the stacker to deal with.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The complete Giardina line runs at 30m/min and can process over 12,000 lineal metres of profiles per shift, single pass with just 2 operators and will pay for itself in 18 months.

 

For more information, 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

SWC Invest In Schubox System

Family run since 1989 and based in Scarborough, SWC Trade Frames is a large regional fabricator of premium quality PVCu & Aluminium windows, doors, conservatory roofs and specialist products such as vertical sash sliding windows, shaped frames and composite doors. They manufacture in excess of 1000 frames per week and supply exclusively to the Trade.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Coating and finishing is key to SWC giving their customers colour choice and with the massive rise in painted finishes, SWC have had a new custom Schubox gas catalytic IR drying system installed in their factory.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The new Schubox will slash drying times for both solvent and waterbased PVC and GRP coatings from multiple hours to just 45 minutes. The Schubox uses an intrinsically safe gas catalytic infra-red technology to cure the coatings very rapidly at a low temperature of 35-38c. This improves quality, reduces work in progress and means the turn-around time for sprayed product is cut dramatically.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Rhys Richings, MD of SWC says “The Schuberts guys from start to finish were fantastic & we’ll certainly pass on our recommendations”

 

Chris Widdowfield, Engineer at SWC says “Had the pleasure of engaging a very professional, friendly, and knowledgeable team of installation engineers this week. A lovely job well done. Thank you Schuberts.”

 

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

 

WINDOOR 2017, Toronto, Canada

 

 

 

 

 

 

 

 

 

Come and see us at Windoor 2017! 28-30th November.

Stand 379.

We’ll be launching our Schubox and Kit-Cat ranges into the Canadian market. Gas catalytic IR drying systems for GRP, ABS, PVC and glass.

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

DOORCO Ltd Invest In A Turn-Key Schuberts Finishing System

 

 

@DOORCO Ltd is the UK’s leading innovator in the composite door industry with a reputation for building the highest quality doors to match the increasing industry demands. DOORCO also offers a wide range of door designs that enjoy success in both the commercial and retail sectors and is consistently bringing new products to the market.

 

DOORCO offer 3 levels of supply to their customers:-

Containers direct for large volume fabricators;

Stock orders from their UK warehouses, where they will supply anything from 1 door to mixed pallet volumes;

Prepped door blanks, offering customised door specifications on size/hardware/ and pre-finished, all completed in their modern UK facility and turned around in 4-7 days.

 

 

Renowned for introducing many composite door ‘firsts’, DOORCO is about to launch yet another new approach when it comes to colour. Thanks to its investment in partnership with Schuberts the market leader when it comes to paint drying and finishing, DOORCO is launching a new way of thinking to allow customers of all sizes to achieve the highest quality custom finishes in record time.

 

The investment process started months ago when DOORCO engaged with Schuberts to design a purpose-built flexible spray finishing system. Trials were carried out with their @RegaLead range of coatings at the Schubert Test Centre in Sheffield, where the full process was demonstrated on production-scale equipment. Doors and components are prepped, including being masked off and either etch wiped or rubbed down with special abrasive pads.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Once prepared, the doors are cleaned and either loaded onto the new overhead track or onto adjustable trolleys and moved into the spray enclosure. Here, they are sprayed in a controlled, clean environment. The air pressure is controlled so that no dust-laden air can enter and no vapours can escape. All the overspray is contained in Andreae double layer filter. Noise is kept to a minimum and airflow to a maximum by using fully ATEX rated centrifugal fan sets. These fan sets are inverter driven and controlled automatically by the spray enclosure control panel, meaning airflow rates are always kept to the correct level, up until the overspray filters are ready to be changed.

 

 

 

 

 

 

 

 

 

 

 

 

All the mixing and colour matching is carried out in a new purpose-built paint mix room. A bunded floor to collect spills, ATEX heating, permanent extraction, filtered air input and a custom workbench all mean it’s a safe and clean room to get those colours right, first time.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

After coating, the 2k coated products are placed into a dedicated flash-off zone. This area is fed with filtered air input and low level extraction. The temperature is slightly above ambient to allow the coating to flow, vent and start to knit into the surface of the GRP composite door.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The key to the super-fast turnaround for DOORCO is the Schubox. This non-standard intrinsically safe Schubox drying system allows their full range of water based or solvent based coatings to be cured in a fraction of the time at the lowest of temperatures with the cleanest of processes.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The Schubox runs at just 35c and completely dries the products in 30-40 minutes before either returning back into the start of the process for a second colour or taken off the line and fitted up ready for shipping. The technology inside the Schubox has been specifically designed to work at low temperature and will not affect the substrate as hot air gas systems do. Long wave IR, air movement, reflection and an elevated temperature allow the Schubox to dry product in record-breaking time!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Matthew Le Masurier, DOORCO’s Senior Production Manager comments: “Colour represents 60% of DOORCO’s sales and the trend is relentless. With the demand for colour comes the demand for paint.  That’s why we took the decision to invest in the Schubox® system which is universally accepted as the most advanced and efficient IR drying and curing system of its type in the world. It will help us to ensure we maintain control of supply and continue to meet the necessary lead times, regardless of colour. In a nutshell, the new finishing line means that doors will dry in 30 minutes compared with 3+ hours. This increases our capacity because as everyone knows, the main bottleneck in painting is the drying process. Schuberts have been fantastic to work with from start to finish and we look forward to passing on the benefits of this investment to our customers when production starts this month. “

 

 

“We feel the real-world value of all our recent operationally investments, including the Schubox is immeasurable. We understand the high value attached to customers’ peace of mind that their doors will be delivered on time, every time even when they’re coloured. Unlike some manufacturers with a simpler business model, automation for DOORCO is critical because we have such a diverse spread of customers, ranging from one-off prepped doors to containers. Each one is important to us. It’s thanks to the investment we’ve already made on behalf of the supply chain and are continuing to make, we can ensure we’ll continue to raise bar on our customer service and delivery on robust operational targets, whilst staying at the forefront of product quality and new innovation especially when it comes to colour.”

 

 

To learn more about DOORCO’s high quality offering for composite doors, contact info@door-co.com

 

If you want to explore custom made Schuberts finishing systems for GRP composites, contact sales@schuberts.co.uk

 

#DOORCO #finishing #composites #grp #schuberts #schubox

Kolorseal Go The Schubox Route

@Kolorseal Ltd, based in Dewsbury West Yorkshire, is the UK’s leading specialist provider of UPVC profiles, glass & metal colour coating, primarily servicing the Fenestration Industry. With over 20 years’ experience they pride themselves on the quality of their service which is backed with a 100% ‘no quibble’ guarantee of satisfaction.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Kolorseal have just commissioned a custom dimension Schubox catalytic IR drying system to eradicate the bottle-neck of drying and curing for both their water and solvent based coatings. The new Schubox replaces a hot air system previously installed. Not only is the Schubox far quicker with a better quality finish, the running costs lower, but the footprint is much smaller. Assembled product, full size GRP composite doors, PVC lengths and aluminium profiles are all put into the Schubox.

 

Live trials were carried out in the new Schubert Test Centre and based on these tests an order was placed. 8 weeks later Kolorseal are up and running in full production.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The Schubox is fed with wet coated product from three large spray enclosures, so not only does the quality have to be kept high but the volumes are also significant too. Drying times are down from 8-10 hours to 30-40 minutes at just 30c!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The Schubox technology uses intrinsically safe gas catalytic infrared to drive off the solvent or water based carriers, to leave a perfectly dried surface. Stainless steel, air recirculation, long-wave infra red and a low temperature of just 35-38c mean the system doesn’t alter the temperature sensitive nature of the Kolorseal production.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Debbie Hendry, MD at Kolorseal says “ Our old system worked for us, but was a lengthy process. The new Schubox speeds up our drying times immensely.  Schuberts were very helpful and knowledgeable. Their installation team were professional and punctual. I would definitely recommend!”

 

To find out how Schubox infrared technology can eliminate your drying bottleneck for the finishing process, email sales@schuberts.co.uk

To contact Kolorseal and find out how they can help you with outsourcing your high quality coating requirements, email sales@kolorseal.co.uk

#kolorseal #finishing #schubox #quality #dryingsystems #composites #grp

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