We’ll be on the @Regalead Stand @fitshow 2017 – come and see us to discuss all your spray finishing and drying plant requirements!
Birmingham NEC 23rd – 25th May 2017
Stand E33.
#fitshow #technology #finishingsystems #regalead
@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 Ltd, based in Dewsbury West Yorkshire, is the UK’s leading specialist provider of UPVC profiles, GRP doors, 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
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.
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.
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.
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.
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.
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
Along with their Polish agent, Artech, Schuberts have just installed a new custom built dual-use finishing system for Nawrocki Group, Bochnia.
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.
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.
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.
Thankfully, after analysing the problems, running tests at another Polish customer, Schuberts had the answers!
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.
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.
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
The next role to be created is that of a Schuberts Service/Installation Technician.
Prior experience of site fabrication installation work will be seen as favourable attributes.
The role is to be based at the new site at Provincial Park, Sheffield, but will involve site/field work both in the UK and also occasionally outside the UK in mainly EU export market countries.
Full job description available on request.
Please share and send email CV’s to sales@schuberts.co.uk
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.
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.
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
A new Schuberts double installation has just been commissioned in Muscat, Oman.
This installation was designed for two separate finishing systems within the manufacturing site in Ruwi, Muscat.
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.
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.
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.
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.
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.
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.
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
Schuberts have recently installed and commissioned a new panel spray machine, heavy duty stacking machine and clean room at one of the UK’s leading producers of specialist door coatings. This is a totally unique and special installation, meaning anything from a kitchen door front, mouldings and up to full size 130kg doors can be processed.
The line incorporates a wide 1300mm automatic spray machine, capable of running at 5m/min. This machine features twin oscillating arms, fitted with 3 separate paint circuits and up to 8 guns. This machine is able to spray primers, base coats and top coats in both water based AND solvent based finishes.
The unique recovery system allows the paint overspray to be reclaimed, filtered and blended back into virgin paint product where possible.
The LIFT system means that up to 130kg doors can be unloaded wet from the spray line and then placed automatically into heavy duty drying trolleys. Each product has its length and width measured automatically before being loaded into its own individual space in the trolley. Once full, the operators move the trolley within the clean room.
The clean room is designed as a flash-off zone and allows the wet coating, specifically high gloss, to be in a clean area before being dried. The flash-off zone here is large enough to accommodate up to 8 full trolleys. The air flow is filtered using capture and hold air input filters and the extracted air goes to atmosphere.
For more information on the range of automatic spray machines for panels, doors and components, email sales@schuberts.co.uk
Schuberts installed a new flash-off zone and gas catalytic IR drying zone to service the finishing needs of both hand sprayed products as well as wet panels coming from a fully automatic Giardina spray machine.
The customer sprays solvent based high gloss PU as well as solvent and waterbased matt paints and lacquers. With the Giardina spray machine able to run at and above 6m/min, the bottleneck was always the flash-off and curing time, not to mention issues with contamination and variation in finishing quality when the wet product was left in the open factory environment. The new Schubert installation addresses each of those issues in three key ways.
A dedicated flash-off room was designed and built around the outfeed conveyor of the Giardina automatic reciprocating spray machine, where wet product is loaded onto drying racks. The flash-off is fitted with a pressurised heated air balance system via a biomass boiler, whereby the 18c input air is matched to the air extracted. All heated incoming air is filtered to remove any particulate and the extract air is fed into the modified Schubox catalytic infra red drying system. The permanent extraction system is at low level to remove the VOC’s.
Once flash-off has happened, the racks are transferred into the dedicated custom Schubox drying zone.
This area is fitted out with 5 gas catalytic heater panels, providing heat, long wave infra red and air movement at a gentle 35-40c. A dedicated control panel serves the whole of the new installation from a central point from an easy to use touch-screen HMI.
Drying times are slashed, productivity is up, reworks are down and Schuberts have another satisfied customer!
