Fully integrated and automated turnkey powder coating systems – from feeding to grinding – are being launched by Baker Perkins at the European Coatings Show at Exhibition Centre Nuremberg, Germany, 28th – 30th March, 2023.
An innovative generation of twin-screw extruder and a new cooling conveyor are the keys to this major development. An HPX35 extruder and Baker Perkins’ new cooling conveyor will be on show, together with a Kemutec Easy-clean air classifier mill.
Visit us in Hall 4A stand 4A.308 for the full story.
Full details of the show can be found at www.european-coatings-show.com
Single source, fully automated, integrated powder coating systems
Schenck Process Group companies Kemutec and Baker Perkins now manufacture in-house all the equipment for a complete powder coating process line – comprising weighing and feeding the mix before the extruder, and cooling, flaking and grinding after the extruder.
Single source supply brings significant gains. There’s the time-saving convenience of working with one organisation and avoiding the potential aggravation caused by multiple suppliers. Aftermarket service for spare parts, upgrading and trouble-shooting is also more responsive.
The ability to fully integrate a complete powder coating line from feeding to grinding, with a single control point for the entire system, creates substantial opportunities for upgrading performance. It transforms the process from a series of separately controlled functions to one cohesive operation.
Integrated systems have a single touch-screen HMI providing clear, at a glance visualisation of the whole process with current status of all major components and parameters.
Key benefits include alarm management to quickly resolve problems and identify trends; data logging and reporting of all process parameters to control quality and process optimization; recipe driven set-up to minimize start-up time and reduce labour and waste.
New High Power extruders with MAX³ feed system
We will highlight our new HPX High Power twin-screw extruders delivering superior outputs on powder coating and specialist chemical applications from a smaller barrel, with reduced cost of ownership and machine down time.
Increased power and speed are the key attributes of the new HPX45 and HPX35 extruders, achieved by full utilisation of the motor through torque stability provided by the patented MAX³ feed system, and increased thrust capacity of the solid-shaft drive train.
A full range of HPX extruders is being developed, capable of handling a full range of powder coatings and toners, including the most intensive formulations. The MPX series will be retained for powder coating applications requiring through shaft cooling.
The HPX retains all the latest features of the MPX range. As well as the MAX³ feed system these include a hi-cool barrel increasing efficiency and allowing lower melt temperatures; a split stuffing box for increased access; a pivoting main feeder for easier calibration and emptying; and purge feeders for quicker turnaround between batches. Noise is minimised by using water cooled main drive motors; a hi-cool discharge adaptor and non-stick coating minimise product hang-up at discharge.
The MAX³ feed system incorporates a fundamental re-design of the extruder intake feed port and screws. It improves the flow of material into the extruder barrel and air out of it to eliminate material build up in the extruder infeed that leads to restricted output and torque surges.
The system brings proven 40 to 100% throughput benefits; top feeding creates improvements in operation that significantly reduce cost-of-ownership compared to side feeding.
New Baker Perkins cooling conveyor
Baker Perkins new cooling conveyors are designed to match the outputs of the HPX and MPX series of extruders. The range of stainless steel belt conveyors provides the cooling efficiency and evenness of flaking that are essential to maximise product quality.
Their introduction is key to the development of turnkey, fully automated powder coating process lines. Once extruder and cooling band operating parameters are defined for a specific product, one-button production start-up and fully automated shutdown are achievable.
Increased production time through effective maintenance is critical, and integration into the line control system allows automated cleaning of the cooling conveyor, minimising risk of cross batch contamination, and increasing operator safety. At the beginning and end of a production run the calendar roll section retracts and a container is automatically positioned to capture waste material.
The flaking unit has its own air vortex cleaning system for dust extraction, cutting labour and turnround time whilst ensuring high quality product with low contamination risk.
Additional features include easy access to squeeze rolls that can be inched in reverse for cleaning; and quick release spray bars for ease of changing blocked nozzles.
New Kemutec mill – applications include fast-paced recipe changes
Kemutec will display the new PPS Easy-clean Air Classifier Mill. Ideal for hygiene-focused food applications such as dairy and those that require fast-paced recipe changes, most prominently Powder Coatings, the Easy-clean Air Classifier Mill combines ultra-fine, highly controlled particle size reduction with a design that enables faster, more hygienic cleaning processes.
The mill’s unique easy-clean design allows unhindered operator access to the unit’s internal workings, thereby allowing faster parts removal, more thorough cleaning and increased operational up-time.
The PPS Air Classifier Mill is used for milling and grinding heat-sensitive material and provides precise control over “particle cut point” selection, by incorporating an internal air-classifying.
