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

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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

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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

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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

UK Timber Door Manufacturer Goes the Schubox Route

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One of the UK’s market leading supplier of wooden doors and associated products has just installed a new finishing system from Schuberts.

Their brand name can be found in the most prestigious names in the Builders Merchants and Retail sectors across the UK with in excess of 400,000 internal and external doors sold per year.

 

The new system comprises of two custom dimension centrifugal spec spray booths with canopies, lighting and custom duct work, plus a new custom Schubox gas catalytic infra red drying system. The input air is pre-filtered through capture and hold filters in the spray shop sliding doors.

 

 

 

 

 

 

 

 

 

 

 

 

The doors are pre-sanded, base-coated in the spray booths, dried in the Schubox, then denibbed, top-coated and back into the Schubox one final time.

 

 

 

 

 

 

 

Typical Schubox drying times with their high-build waterbased coatings are just 30 minutes at 35c, cutting previous drying times down from 3-4 hours per coat!

 

For more information on how Schuberts can streamline your finishing processes, email sales@schuberts.co.uk

Keylite Dry In Record Time With Schubox Technology

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Keylite Dry In Record Time With Schubox Technology

 

 

Keylite offer a full range of roof windows, blinds, timber loft ladders, flashings, electric operation kits and accessories and is Europe’s fastest growing roof window manufacturer.

Underpinning their 10 year warranty is a high quality coating finish and when sales volumes increased, this became a production bottleneck. Keylite turned to Schuberts for an affordable quick curing process for their waterbased coatings.

Full production trials were carried out with Keylite substrate, their own range of coatings and their production methods, in the Schubert UK Test Centre Schubox system. This proved that under real conditions, the Schubox system can more than half the drying times of their finishes.

 

 

 

 

 

 

A custom dimension Schubox was ordered and then 7 weeks later was installed in Zambrow, Poland. This Schubox employs long wave gas catalytic infrared technology via heating panel emitters.

 

 

 

 

 

 

 

 

Running at just 38-40c, it is able to accept racks of wet products and dry them properly in record time, without affecting the substrate.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Jim Blanthorne, Keylite International Operations Director, says “We are delighted with the performance of the Schubox. There have been immediate improvements in quality, cycle time and capacity. This, the latest in a series of investments, will ensure we continue to supply our range of innovative and award winning products in line with our ambitious growth plans”.
For more information on Keylite products, see www.keyliteroofwindows.com

 

To see how the Schubox can improve your throughput and deal with that drying bottleneck, email sales@schuberts.co.uk

A RICH LEGACY IN WOODWORKING – BURBIDGE INSTALL SCHUBERTS FINISHING SYSTEM

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A RICH LEGACY IN WOODWORKING – BURBIDGE INSTALL SCHUBERTS FINISHING SYSTEM

 

 

 

 

For well over 35 years Burbidge have been manufacturing and distributing kitchen doors and accessories. Over these years they have developed an intimate knowledge of wood production and honed their ability to revive, reinvent and modernise classic design.

“Quintessentially British”, the Burbidge collection illustrates how in every design their passion for fine kitchens never fails to shine. With the many of their ranges produced in at local UK factory sites their unique heritage as a British manufacturer provides inspiration whilst keeping their perspective fresh and contemporary.

Burbidge wanted to increase their sprayed production, whilst improving quality and quicker delivery times and engaged Schuberts to design a custom finishing system to not only be able to deal with an automatic spray machine, but also hand sprayed products in both 2k PU and water based. Their range of coatings go from matt, satin and gloss onto many different solid species of solid wood, MDF and vinyl wrapped doors and carcasses.

 

 

 

 

 

 

 

The new finishing system from Schuberts combines a clean flash-off room that not only accepts product from an automatic reciprocating spray machine, but also trolleys from hand-sprayed production. A slotted entry means the outfeed from the spray machine delivers the wet-coated parts directly the an operator who is able to manually load onto racks OR bring fully loaded racks directly into the flash-off via double sliding sealed doors.

 

 

 

 

 

 

 

Once the product has flashed off and allowed to flow and settle, the racks are introduced into the custom-built Schubox drying system, via special bi-fold doors to minimise door sweep.

 

 

 

 

 

 

 

The Schubox is designed to dry both solvent and water based coatings very quickly at a low temperature. This means a drying time of between 30 to 50 minutes on all of Burbidge’s range of coatings. The combination of gas catalytic long wave infrared, reflected infrared, air movement and 35-38c means the Sherwin Williams coatings are not ‘skinned over’ and dry properly through the coating thickness.

 

 

 

 

 

 

 

Once the products have been in the Schubox for the correct amount of time, they can either be turned over and sprayed the other side or denibbed and recoated to get the high quality finish Burbidge are famous for.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The bottle neck of drying overnight has now been cured with the new Schubox system., with a better quality, fewer reworks and a much quicker throughput.

For more information on Burbidge’s range of products, see http://www.burbidge.co.uk/

To see how the Schubox systems can reduce your work in progress and improve quality, email sales@schuberts.co.uk

#burbidge #kitchens #schubox #quality #finishing #spraying #bottleneck

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

Nawrocki Group, Poland, Cure Finishing Bottleneck With Schuberts

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Along with their Polish agent, Artech, Schuberts have just installed a new custom built dual-use finishing system for Nawrocki Group, Bochnia.LOGO Nawrocki Group

 

 

 

 

 

 

 

 

 

 

The Nawrocki Furniture Company was founded in 1991 and has grown to be one of Poland’s largest and highest quality manufacturers of furniture, bar fit-out and bath pods.

In its first years, it was dedicated to manufacturing single pieces of home furniture for retail clients. It took only a decade for the company’s portfolio to change, as implementation of interior furnishing for public buildings, such as hotels, restaurants, banks, office buildings became its dominant element.

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Production abilities of the company, which was capable of manufacturing furniture that reached the standard of both two and five star hotels, made the investors from hotel branch a main target group of F.M. Nawrocki.

Numerous implementations throughout the whole Poland left the way clear for the services expansion into French market in 2002. High aesthetic and functional standard of furniture, foolproof logistics of the business and the knowledge of French legislation were the reasons why in 2005 The Nawrocki Group Company was awarded with The Silver Medal for The Best Service offered on French market, given by Polish Trade Organization.

By 2015, F. M. Nawrocki have furnished over 200 high standard hotel buildings in the whole of Europe (including 150 hotels in nearly 100 French cities), obtained regular references from Orbis hotel chain and successfully intensified its services on Anglophone markets.

The sister company Nawrocki SDB was founded in 2013 and it is the business based on manufacturing and installing prefabricated bathroom pods using wood and GRP substrates.

 

One of the bottlenecks of such successful and rapid growth was the spray processing and finishing of furniture and GRP bath pods. Drying times, variation in ambient temperatures, types of specialist paints and lacquers etc, all contributed to a complex and unique production request.

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With the Nawrocki production being split between both flat panel and 3D carcass production lines, they needed a flexible high-volume system capable of meeting the very highest quality levels of finishing.

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Thankfully, after analysing the problems, running tests at another Polish customer, Schuberts had the answers!

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A dedicated flash-off zone was designed to not only take wet product from the manual spray shop, but also to accept, via a special outfeed conveyor, wet product from an automatic panel spray machine.

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This dual-use installation not only means that high volumes of product can be coated and cured in record time, but the quality is kept to its absolute maximum.

Once the product had ‘flashed-off’ the trolleys and carcasses are loaded into a Schubox gas catalytic IR curing system at 40c for around 30 mins.

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After drying inside the Schubox, the products are removed, either de-nibbed for the next coat or sent directly to packaging.

 

What used to take 3 days, now takes hours….!

 

For more information on finishing systems, manual and automatic, email sales@schuberts.co.uk or for Poland email poczta@malserw.pl

 

 

Joinery Firm Reduce Finishing Bottleneck

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Want A Quick and Easy Way To Cure Your Paints Quickly? North West Joinery Coatings Have!   North West Joinery Coatings have just invested in a new gas catalytic infrared curing system from Schuberts. This retro fit uk installed system is based around flameless infrared technology and consumes either LPG or natural gas in a […]

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Services and Trade Interiors and Contracting, Oman, High Gloss Systems Installed

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A new Schuberts double installation has just been commissioned in Muscat, Oman.

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This installation was designed for two separate finishing systems within the manufacturing site in Ruwi, Muscat.

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Phase 1 featured ATEX rated open spray booths and custom ducting to atmosphere. These booths were fitted with Andreae high efficiency double layer filters. These open booths are used for primers, base coats, stains and satin finishes on GRP, glass, wood and plastic.

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Phase 2 was a large complete water-wash stainless steel installation for solvent based gloss product onto wood, GRP and glass substrates.

The 6000mm x 7000mm spray enclosure has a double filtration system for the air into the spray zone. Firstly, air from outside the factory was filtered by an existing air handling system and then the air undergoes a further cleaning through capture and hold air input filters on top of the Schubert spray enclosure.

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The paints and lacquers can be applied by up to 3 sprayers working on rotating tables, against a full water-wash extraction system. A cascade of water takes away the overspray with recirculated water flow into a base hopper tank for overspray capture. This system has a high capacity recirculated water flow with fresh water top-up system, allowing increased flow to the scrubber nozzles, whilst minimising the volume of water inside the water wash spray booth.

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Lighting is provided by roof and wall 1000 lux blue/white flicker free sky-white lighting systems. This is the closest to natural light and perfect for the spray application of clear coats and pigmented paints onto a variety of substrates, including solid wood, veneers and glass.

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All intermediate storage of paint tins is inside a special paint mix room, adjoining the spray enclosure. This features a bunded floor, ATEX lighting, ATEX heating and permanent extraction to atmosphere via an ATEX rated fan set and ducting. Also this paint kitchen features explosion relief panels and twin personnel doors for emergency escape routes.

Once sprayed inside the spray shop enclosure, the wet racks of product are transferred into a 12,000mm x 3000mm flash-off zone. This area is to allow the solvent vapours to ‘flash’ prior to being force cured in the Schubox drying system. The flash-off zone is fitted with filtered air input to ensure a clean zone. There are low level, full-length, extraction chambers, ATEX fans and ducting into the Schubox for oxidisation.

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After flash-off (5 mins for water based, 10 mins for acid catalysed and 40 mins for high gloss PU), the products are placed inside the Schubox for drying and curing. The Schubox is a long-wave, gas catalytic infra red drying system, designed to run at low temperatures and cure wet coatings very quickly. This Schubox in Oman, runs at 40c and cures solvent polyurethanes in 45 minutes (compared to 2 days in the past!). The Schubox has filtered air input, air movement, full stainless steel construction and custom made infeed and outfeed doors.

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For more information on high gloss finishing systems for wood and glass, spray booths, rapid drying and all Schubert systems, email sales@schuberts.co.uk