Powder coating process is the method that is for making the final product. It is industrial process to paint the metals of other related products. Basically in this process we need some instruments and materials. Please find the process points below.
Let’s say, our product is manufactured and ready to coat. We will start with PT lines/ Pre Treatment line.
Typically, adhesion between a paint coating and steel sheet is not very good. That’s why in Powder coating process, it is recommended to apply some type of intermediate layer, a pretreatment, to develop good long-term performance. Not only does the pretreatment improve the mechanical adhesion between the paint and the coating, but it also improves the resistance to blistering and loss of paint adhesion during exposure to corrosive environments.
Steps are:
Hot Water Rinse
Knock-off-Degrease
Degrease
Water Rinse
Water Rinse
Activation
Phosphating
Rinse
Drying
After Pretreatment, out product is ready for powder coating, now we will take our product to the Powder Coating Booth. With the help of manual gun or reciprocators we will apply charged powder on the surface, let’s see how.
Pollution free powder coating booths are most efficient, as there is no wastage, neither causing any issue to the environment. These are build as per the industry standards so you can have the best product finish with minimum wastage.
No powder escaping the booth:
Gema recovery systems are designed according to the strictest safety regulations and the specific requirements of each plant.
After Filter units for MonoCyclones: These filters are installed after the cyclones. They use self cleaning cartridges and reach over 99.99% separation efficiency. Powder from the filter can be imediately recirculated to the guns.
Filter Units for manual and small automatic lines: These reliable filter units are equipped with conical cartridges and use a manually activated jet cleaning system
Gema Powder Coating booth are designed in such a way, that they are at maximum performance all the time and when you need to change the color, You can do it very quick. We are going to explain about the features of the Quick color change booth.
Magic Systems are easy to customize in booth dimensions, air volume, number and position of guns and touch-up stations.
Efficient powder application
Sieving and fresh powder feed
Robust and reliable for every need
Lets Check the Powder Flow :
From the feed station the powder is transported to the electrostatic guns that charge it and apply it on the parts.
The final filter separates the overspray powder from the extraction air.
A recovery pump transports the powder to the sieving station where powder is cleaned from contaminants and returns to the powder feed station.
The system can be provided with various automatic fresh powder feed solutions
Ideal solution for every customer’s needs:
EquiFlow technology can be used in different layouts to accommodate every customer’s needs
Great performance, robustness and easy maintenance in every solution
MagicCylinder EquiFlow, the unique round-booth solution
A broad range of reliable reciprocators, easy to use and to maintain, improving the coating quality and saving manpower.
Stand-alone vertical basic reciprocator:
Perfect entry-level model for customers from different markets and various application demands.
High power for many guns
Stand-alone reciprocator with slim column design allows space-saving arrangement of up to 6 automatic guns (25 kg capacity).
Flexible with vertical or horizontal guns arrangement
The reciprocator is designed for short or long stroke operation. The guns can be mounted in horizontal or vertical arrangement.
Designed for smooth operation
These reciprocators is equipped with an advanced synchronized motor for highest efficiency during continuous operation.’
Easy service and great reliability
The reciprocators require only minimum maintenance that can be completed easily and quickly.
Powerful and reliable
Main Features Overview:
High power for many guns
Reciprocators have a high load capacity, they can carry a high number of guns with extreme precision and high reliability.
Flexible with vertical or horizontal guns arrangement
These reciprocator is designed for short or long stroke operation. The guns can be mounted in horizontal or vertical arrangement.
Reciprocator version for a high loading capacity
Capable to carry up to 100kg.
Designed for smooth operation
The frequency converter controlled AC-Motor drive, the long lasting thooth-belt and the robust design ensure a quiet operation and great stability.
Easy service and great reliability
The reciprocator is designed for short or long stroke operation. The guns can be mounted in horizontal or vertical arrangement.
Automatic speed adjustment to conveyor speed
The MagicControls track the conveyor speed and automatically adjust the reciprocator to the ideal speed for perfect sinus and great coating results.
Vertical reciprocator: for extreme high loading capacity
Extreme powerful reciprocator with space-saving design, very precise movements and easy programming.
Extreme high loading capacity
Reciprocators have a high load capacity up to 100 kg. They can carry a high number of guns and ensure very precise gun positioning and reliable operation.
Space-saving guns arrangement
The reciprocator is designed for short or long stroke operation. The guns can be mounted in horizontal or vertical arrangement.
Gun axis and vertical reciprocator arrangement
This combination guarantees perfect coating results for complex application demands and difficult part geometries.
YT synchronizing axis
XT horizontal axis
It moves a ZA vertical reciprocator in and out of the booth adapting to the part width. Ideal solution also for guns outside cleaning at color change.
YT synchronizing axis
It moves a ZA reciprocator parallel to the parts, synchronized with the conveyor speed. Ideal for inside coating and other difficult applications.
U in-out axis
The U axis moves 1 or 2 automatic guns in-out. It is ideal for guns positioning and inside coating.
AR rotating axis
This axis can turn 1 or 2 guns over a fixed radius. It is ideal to coat round shaped objects such as wheels or loading openings of washing machines.
SR tilting axis
This axis can tilt a ZA reciprocator in-out of the booth. It is ideal to achieve a uniform coating on inclined surfaces.
Vertical reciprocator: for extreme high loading capacity
Extreme high loading capacity
Reciprocators have a high load capacity up to 100 kg. They can carry a high number of guns and ensure very precise gun positioning and reliable operation.
Space-saving guns arrangement
The reciprocator is designed for short or long stroke operation. The guns can be mounted in horizontal or vertical arrangement.
Gun axis and vertical reciprocator arrangement
This combination guarantees perfect coating results for complex application demands and difficult part geometries.
Designed for smooth operation
The frequency converter controlled AC-Motor drive, the long lasting thooth-belt and the robust design ensure a quiet operation and great stability.
Easy service and great reliability
The reciprocators require only minimum maintenance that can be completed easily and quickly.
A wide variety of solutions for the electrostatic manual coating to satisfy even the most challenging application requirements.
Easy and automated color change process
All components in contact with powder are cleaned quickly and automatically while the operator is replacing the powder box.
Power: Maximum coating performance
The newly developed PowerBoost technology of the OptiFlex Pro series offers with the 110 kV the highest powder charging capacity in the powder coating industry while complying with safety regulations.
The operator benefits from an outstanding coating performance.
Quality: Best application results
With OptiFlex Pro you coat extremely efficiently and with consistently high quality. The PCC (Precise Charge Control) mode regulates the spray current even in the lowest ampere ranges (0-10 μA) with the highest accuracy. This prevents overcharging of even the most demanding powders such as metallic powder and ensures the highest quality in thick film and multi-layer applications and recess areas.
Control: Master the application!
The new features of OptiFlex Pro also give you a technological edge. The Electrostatic App (E-App) with the integrated line management functions and service features make the coating process transparent and better controllable.
More Power Performance
Thanks to Gema’s PowerBoost® technology manual gun can now deliver 110 kV high voltage!
This outstanding feature gives you extra power to increase transfer efficiency, charge more powder and finish your coating job quicker. All this without compromising the safety of your operators and of your line, thanks to Gema’s advanced protection technology.
PowerBoost: how does it work?
The high-performance technology is based on the combination of three essential components:
● OptiStar 4.0 advanced software for charging process and compliance with safety regulation
● OptiSelect Pro high performance cascade
● NF40 PowerBoost nozzle special design for more efficient charging
NF40 PowerBoost Nozzle
PowerBoost Nozzle characteristics:
● Cloud soft could
wide brush spray pattern >60°
● Material non stick high quality materials
(PTFE / ETFE / PP)
● Application ideal for large parts and fast
coating
PowerBoost: Maximum Coating Performance
PowerBoost: activating
● Direct switch on manual gun OptiSelect Pro
● On OptiStar 4.0 by selecting spray voltage above 100kV
● E-App by typing spray voltage above 100kV
Digital Valve Technology (DVC)
Thanks to the patented DVC technology, Gema’s OptiStar gun controls offer precise and reproducible powder output regulations and improve the film thickness consistency
DVC technology: how does it work?
Digital Valve Control (DVC) is the technology used in the OptiStar gun controls.
The flow of compressed air to the OptiFlow injector is regulated by motor-driven valves.
The first choice for efficient manual coating
The OptiSelect Pro gun is characterised by a very robust and durable design. The ergonomic gun lies balanced in the hand, has a good grip and enables you to coat efficiently and faster.
PowerClean for fastest color changes
PowerClean™ efficiently cleans the entire powder path from the injector to the gun tip. This improves performance when processing difficult powders and facilitates color change.
Unsurpassed Gema reliability
The famous Gema guns’ reliability is based on more than 50 years of experience in powder coating and on the high Swiss quality standards. OptiFlex Pro is using a compact setup to deliver the powder to a standard OptiSelect gun.
Optiflex Pro is the revolution in the powder coating industry. It is the most advanced in features. It is designed in a way to increase the plant efficiency to more than 20%.
OptiFlex Pro closed hopper protects powder from the ambient and gently fluidizes it for an ideal powder delivery.
Gema’s PowerBoost® technology your OptiSelect manual gun can now deliver 110 kV high voltage.
This outstanding feature gives you extra power to increase transfer efficiency, charge more powder and finish your coating job quicker. All this without compromising the safety of your operators and of your line, thanks to Gema’s advanced protection technology.
Reasons to opt for Optiflex Pro :
Robust and durable design
The ergonomic and light-weight gun is well-balanced in the hand
Enables you to coat efficiently and faster
PowerBoost® – Safe technology for more power performance
The integrated cleaning of the powder conveying components can be enhanced by the optional PowerClean™ module
The latest generation of nozzles ensures an excellent powder distribution and penetration
The newly developed PowerBoost technology of the OptiFlex Pro series offers with the 110 kV the highest powder charging capacity in the powder coating industry while complying with safety regulations.
The operator benefits from an outstanding coating performance.
The new feature completes the proven high-voltage functionalities, such as PCC mode, presettings and individual coating programs and extends the application range significantly.
OptiStar® 4.0
Precise Charge Control Mode (PCC) for high-quality coating tasks
The intuitive display makes it easy for any user to set and program the optimal parameters.
The result is a perfect coating quality that can be reproduced at any time.
Digital Valve Control Technology (DVC) for precise powder delivery
Electrostatic App (E-App) for transparency of the coating
Electrostatic App (Gema E-App)
The new features of OptiFlex Pro also give you a technological edge.
The Electrostatic App (E-App) with the integrated line management functions and additional service features make the coating process transparent and better controllable.
Important data of your application are always at hand and can be easily exported for further usage.
To revolutionise your production, opt for Optiflex Pro, to know more about this, Contact us or drop an enquiry
Quick color change or single color, manual or automatic, organic, or enamel powder, Gema has the right solution for you.
Compact and flexible single channel booth design:
A versatile concept combining pre/post touch up and a large automatic application area in a compact design, ideal for easy and quick cleaning.
Non-conductive walls for cleaner operation
Magic Systems remain clean during operation: the non-conductive plastic walls and the self-cleaning floor prevent powder accumulations.
Non-conductive walls: how do they work?
Traditional sheet metal booth walls are conductive and attract charged powder particles that accumulate in thick layers on their surface.
Magic Systems’ plastic sandwich walls are non-conductive and do not attract powder.
Only a small amount of powder particles can deposit on the non-conductive walls. The charge of the deposited particles creates an electric field that repels powder.
Air-knives: how do they work?
Air-knives are integrated into the sidewalls of the Magic Systems’ floor.
During operation and cleaning air blasts are periodically released by the air knives.
The air blasts remove the powder accumulated on the booth floor and push it to the extraction and recovery system.
The booth floor remains clean, with just a minimum amount of powder.
Easy and quick color change:
Magic Systems have very low powder accumulation, therefore the operator can clean the walls and the floor easily and quickly with an air lance.
The risks to blow powder out of the booth and to contaminate the ambient are minimized.
The risk of color contamination due to improper booth cleaning is also minimized.
The color change is easy, quick, and contamination-free.
EquiFlow: an intelligent airflow distribution
The patented EquiFlow technology ensures a powerful air extraction at the booth openings and a gentle airflow in the automatic section.
EquiFlow: how does it work?
● The “H” shaped air extraction slot on the booth floor creates an ideal airflow distribution.
o 40% air extraction in the automatic coating area
o 2 x 30% air extraction at entrance / exit, close to the touch up stations
● The EquiFlow Intellectual Property is protected by Gema
Ideal airflow distribution
• The EquiFlow Technology creates ideal working conditions in each section of the powder
coating booth
• A smooth and homogeneous airflow in the central area ensures ideal powder application conditions for automatic coating.
• A vigorous airflow at the entrance / exit avoids powder escaping the booth and creates optimal working conditions for the touch -up operators.
Easy color change
● Single channel concept reduces the cleaning efforts.
● Simple and easy to clean channel geometry.
● Cleaning tool provided for easy and accurate channel cleaning.
● Automatic air -knives in the booth floor prevent powder accumulations
● A stable walk-in booth floor allows easy cleaning of the walls of the booth.
Best performance for coating large parts
A versatile range of booths systems, specially designed to ensure optimal coating performance and good color change time even with large parts.
A complete range of solutions for every need
Magic Systems are easy to customize in booth dimensions, air volume, number and position of guns and touch-up stations.
Automated color change process
With Gema Magic Systems the color change process is easy and quick, even with just one operator.
Non-conductive walls for cleaner operation
Magic Systems remain clean during operation: the non-conductive plastic walls and the self-cleaning floor prevent powder accumulations.
Air-knives: how do they work?
• Air-knives are integrated in the sidewalls of the Magic Systems’ floor.
• During operation and cleaning air blasts are periodically released by the air knives.
• The air blasts remove the powder accumulated on the booth floor and push it to the extraction and recovery system.
• The booth floor remains clean, with just a minimum amount of powder.
Best guns for color change
The optimized design, the smooth material and the innovative nozzles make Gema guns the best for color change.
Ideal design of the powder path
● The inside diameter remains constant and the transition between the different parts of the
gun is very smooth.
● These features prevent powder depositions inside the gun and facilitate the cleaning procedures.
Result:
● Straight, deposition-free path
● Constant powder output
