Koch designed & installed the FIRST industrial e-coat system in North America...

Transcription

1 ECOAT FINISHING Koch designed & installed the FIRST industrial e-coat system in North America... Today, Koch has implemented more than 300 high performance systems in a wide range of industries. Environmentally Responsible Solutions In all of our business endeavors, KOCH is committed to providing equipment and services that respect the environment and use the least amount of natural resources possible. Koch Headquarters USA Tel: KochLLC.com

2 THE ART AND SCIENCE OF ELECTROCOATING Electrocoating is a process critical to every segment of metalworking manufacturing. Advanced electrocoating systems allow product designers greater latitude in the choice of materials. Electrocoating systems improve the performance and wear properties of critical components, and give metals a high quality, nonporous, high-adhering surface for the subsequent application of liquid or powder topcoats where desirable. Electrocoating uses electrical energy to apply organic finishes. The part is grounded and immersed in paint that has been charged with the opposite polarity. Resin and pigment migrate to the part, and a uniform film is irreversibly deposited. The part is rinsed, then cured. The most common applications of electrocoating include underhood and underbody components, recreational goods, cooking and laundry appliances, HVAC products and aerospace. Manufacturers of upscale consumer products widely use electrocoating as a primer for powder-coated goods. There are two basic types of electrocoating processes. Anodic systems deposit a negatively charged polymer onto a positively charged part. In a Cathodic system, the reverse is true. George Koch Sons, LLC can demonstrate and help you compare these fundamental options to select the best process for your specific application, your plant, your production and your future requirements. Member of

3 KOCH SYSTEM - Tailored to your needs KOCH sales professionals will work with you, your paint and chemical suppliers and other critical suppliers to design a complete system to meet your particular needs. Our experience with more than 300 systems allows us to guide you through critical decisions on all system modules, including: Material Handling The process by which parts are conveyed through the entire system determines many other design considerations. KOCH provides both continuous motion (monorail, power and free, and continuous belt) and indexing (cross-bar, walking beam, and programmable hoist) systems. Your part characteristics, production requirements, space utilization and other factors will be carefully explored in helping you select the best method of material handling. Surface Preparation Surface preparation is the first and perhaps most critical step in obtaining a quality coating on any product, regardless of the coating process. The cleaning process best suited for your application will be determined through interaction with your paint and chemical supplier. Spray, immersion and sprayimmersion combination cleaning are available. Single and dual-tunnel washers can be provided to optimize process requirements and space utilization. Mild steel, stainless steel, and fiberglass construction are available. Dry-Off For select applications, a drying oven is installed following the surface preparation stages to dry the ware before it enters the electrocoating area. Paint and part characteristics help determine if this step is required. low and maintenance downtime to a minimum. Unique KOCH designs provide users with exceptional flexibility and efficiency. Wastewater Treatment Integrated KOCH systems typically include collection tanks, treatment modules, clarifier, sludge thickener, ph adjust, sand filter and sand filter transfer, water re-use, and flow monitoring.

4 Electrocoating Application The electrocoating tank is constructed of steel plate with an inner lining made of a chemically-resistant, dielectric material. The tank itself is electrically grounded. Current flows from the power supply through an electrode, through the paint to the part, and through the part back to the power supply. Through this process, resin and pigment migrate to the part, and a uniform film is deposited. In anodic systems, the part is positively charged and the paint is negatively charged. The reverse is true in Cathodic systems. Typical dwell times in the tank are from 90 seconds to 120 seconds. Dwell time and part dimensions are two of the key factors in determining the size of the tank. As parts leave the tank, they are moved through two or three counterflow rinse stages to remove undeposited paint. Cure Oven Exclusive KOCH features, including heat recovery, heat exchange tunneling and air seals, give users an important competitive advantage by keeping operational costs

5 KOCH ovens are legendary for reliability, uptime, and temperature profile performance. KOCH has extensive experience with all recognized pretreatment processes, including zinc phosphate, iron phosphate, chromate, and the newest phosphatefree conversion coating Controls offered by George Koch Sons include simple relays to the most advanced Programmable Logic Controls (PLCs), as well as specialty devices, such as those for strategic safety lock-out and electronic data interchange. If building a new electrocoating line or updating an existing one is in your plans, we invite you to visit our headquarters. We also encourage you to talk with current users of KOCH electrocoating systems. Ask one of our sales professionals for a reference similar to your application. There are more than 300 satisfied KOCH E-Coat users from which to choose throughout North America and the world. AUXILIARY E-COAT EQUIPMENT The Power Supply is an AC/DC converter with adjustable constant voltage capacity of Rectifiers delivering DC of less than 5% ripple factor are standard. The Liquid Chiller supplies cooling medium to the heat exchanger in the e-coating tank in order to control bath temperature. Paint Replenishment equipment feeds the electrocoating tanks. If the pigment and resin are furnished separately, the system supplies them, pre-mixed to the specified ratio by a static mixer which is integral to the system. Ultrafiltration Membranes pass water and dissolved substances and collect dispersed paint resins and pigments. The permeate (or ultrafiltrate) is used to rinse the product as it leaves the electrocoating tank. This rinse recovers undeposited paint, which cascades back to the tank through counterflow rinsing. Efficient, well-engineered ultrafiltration allows repeated recycling of undeposited paint, and a resultant material utilization of 99%+. COMPACTCOAT SYSTEM BULK E-COAT MACHINE E-COAT SYSTEM

6 ELECTROCOATING & THE KOCH SYSTEM ADVANTAGES George Koch Sons, LLC specializes in turnkey electrocoating systems that include surface preparation, electrodeposition, curing, waste treatment, material handling and all auxiliary systems. We offer exceptional design and engineering, exceptionally low life-cycle costs, and more than 40 years of success in adapting electrocoating technology to suit the individual needs of customers. Today, and 20 years from now, KOCH s team of electrocoat specialists stand with you to assure that your process, your people, and your production runs smoothly and predictably. LEADERSHIP IN ELECTROCOATING George Koch Sons has long been committed to creating and improving the techniques and technologies that are integral to World Class electrocoating.

7 ECOAT ADVANTAGES Precise Control - High Repeatability Properly engineered systems offer precise control over film thickness, highest film integrity and an unblemished appearance. The process offers extremely high repeatability of results, and is a practical alternative for metal parts of virtually all sizes and shapes, gages and grades. Superior Material Utilization Through use of closed loop rinsing, ultrafiltration and the basic process itself, electrocoating allows virtually 100% material utilization. Environmentally Friendly & Safe Many electrocoat paint formulas are now available which are free of heavy metals; many are also near-zero in VOCs and HAPs. And because the paint is 80-90% water, the risk of fire - the ultimate environmental disaster - is vastly reduced. Energy Efficient Electrocoating may not require a dryoff oven, thus exhaust air and make-up needs are minimized

8 Koch Headquarters George Koch Sons, LLC 10 S. Eleventh Avenue Evansville, IN Koch EUROPE George Koch Sons Europe, Ltd. Tame House, Fradley Park Lichfield, WS13 8RZ United Kingdom Phone: 0044 (0) Koch Mexico George Koch Sons dé México S. R.L. dé C.V. Av. Campanario 99 Int A-11 Col. El Campanario Queretaro, Mexico Phone: Sales Department Sam Woehler Vice President, Sales Office: (812) Cell: (812) Rick Cannon Specialty Products Sales Manager Office: (812) Cell: (812) Ron Cudzilo Regional Sales Manager Central & Western USA N. Forest Kansas City, MO Office/Fax: (816) Cell: (812) Don Miller Regional Sales Manager Southeastern USA Office: (812) Cell: (812) Dan Hostetler Thermal Acoustical Sales Manager Office: (812) Fax: (812) Cell: (812) Todd Turnock Acoustical Distributor Sales Manager Office: Cell: Mexico Sales Antonio Gallegos General Manager, Koch de Mexico Office: Cell: coating systems thermal solutions acoustical solutions environmental conservation material handling GKS080414