Verona Impianti 2002 has designed and installed a new powder coating plant at D.P.F. Srl, a job-shop coating serving various industrial sectors, including furniture and design. The new line, designed to paint items of different sizes, has enhanced the quality of the final finish, reduced energy consumption, and promoted the environmental sustainability of the Padua-based company.
Verona Impianti 2002 has been designing and installing coating plants for over 40 years, studying a wide range of cases and finding reliable, economical, and optimal solutions. For each customer, the company designs a tailor-made solution that pays the utmost attention to their needs and satisfies every single request in the best possible way.
D.P.F. Verniciatura, specialising in contract coating for a wide range of sectors, including furniture and design, has recently relied on Verona Impianti 2002 for the design and construction of a new powder coating plant. This new line, developed to handle items of various sizes, from small parts to heavy components, has enabled the Padua-based company to achieve excellent quality results, reduce energy consumption, and enhance environmental sustainability.
What did D.P.F. Verniciatura need?
During the initial stages of plant design, D.P.F. highlighted the main challenges faced with the previous system: the company's primary objective was to install a versatile plant capable of coating a wide range of parts—both in terms of size and weight—and fill the previous plant’s gaps, particularly concerning the pretreatment cycle.
Another crucial requirement was to ensure outstanding performance and ensure that the parts achieved an aesthetic finish that met the exacting standards of the furniture industry, alongside excellent durability and resistance over time.
Verona Impianti 2002 met these demands by designing a cutting-edge plant, developed according to the principles of Industry 4.0 and equipped with advanced technologies that ensure more analytical management and high-quality production.
What are the plant’s technical specifications and how’s the coating cycle composed?
The parts to be coated are manually loaded on a monorail chain conveyor - capable of transporting up to 150 kg per hook - and subjected to a pretreatment cycle consisting of four stages:
- Phospho-degreasing
- Rinse with mains water
- Additional rinse with mains water
- Final rinse with demineralised water.
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The pretreatment tunnel.
One of the main challenges faced by the company with the previous system regarded the pretreatment process. For this reason, Verona Impianti 2002 developed a series of improvements, such as separating the heating boiler from the tunnel tanks and the feeding method of the spraying ramps, which occurs from above. These adjustments allowed D.P.F. to achieve an optimal cycle that ensured adhesion and long-term durability of the applied coating.
To enhance energy consumption, several measures were implemented: the cleaning tunnel pumps have been equipped with inverters to manage rotational speeds and optimise energy usage. Additionally, water heating is achieved by using the existing photovoltaic panels.
Components exiting the tunnel.
Subsequently, the metal components are transported to the drying oven, where they remain for approximately 13 minutes. They are then conveyed to the paint booth, where D.P.F. carries out a completely customised finishing cycle based on the customer's requirements.
The coating application phase.
Energy efficiency is also ensured by the drying and curing oven: both are equipped with air curtains designed to retain all heat inside and prevent losses, aided by a system that reintroduces hot air exiting from the inlet and outlet openings of the pieces, known as an "economiser." The ovens' thermal consumption is minimised thanks to excellent thermal insulation using mineral wool.
One of the key features is the PLC control system, which allows management of the plant from a terminal. This functionality enables monitoring and control of all critical parameters, including conveyor speed, oven and washing temperatures, ensuring optimal operation and precision in the coating process. The system also includes remote assistance and control, enabling prompt intervention in case of production failures or defects.
The system’s PLC.
The results obtained by the new coating plant
The new plant has enhanced the finish quality, improving the pretreatment cycle with demineralized water cleaning, a crucial factor for the success of D.P.F.
From an energy perspective, the Paduan company has achieved a 40% reduction in methane gas usage: this is a significant milestone aligned with D.P.F.'s strategy focusing on energy efficiency and the use of alternative sources. With the implementation of this new coating plant, the company has strengthened its position in the market and set new standards of excellence in the industry - reaffirming its commitment to quality, sustainability, and innovation.
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ipcm_International Paint&Coating Magazine here: https://www.ipcm.it/it/open/ipcm/2024/86/164-170.aspx