HIGH QUALITY ELECTROSTATIC PAINTING OF ZINC ALLOY TOYS
Custom-designed and built for popular toys and model brand, SIKU, this painting line uses electrostatic painting technology to ensure high quality painting of the items. The painting line was supplied as a semi turn-key project in cooperation with paint system supplier and chemistry dosing supplier. The Moldow design includes all necessary process zones, support zones as well as the critical ventilation and air conditioning.
The aim of the project was to design, install and commission a user-friendly painting line with the required processes fitted into the available space. This ment a highly optimized layout with low physical footprint.
The painting line was supplied with all the necessary process zones: Load/unload, three-stage pretreatment, drying oven, cooling zone, paint application, flash-off, curing oven and cooling zone.
To ensure that the objects are clean and ready for the high-quality painting, the line includes a three-stage pretreatment process carried out in the pretreatment tunnel. The process includes degrease/phosphating followed by a normal rinse and a demineralized rinse.
After the pretreatment, a (water) drying oven and a cooling zone follow to ensure that the items have the correct temperature for the following paint application.
The electrostatic paint application is carried out in an automatic spray booth for most of the items or alternatively in a manual booth for very small or special parts. Both spray booths are with dry filtration including filters with high overspray capacity.
The automatic spray booth –a so called Omega booth– is octagonal with the items entering and leaving the booth through the same opening. While the items are transported through the booth on the conveyor, the jigs also rotate to ensure an even paint application.
The spray booths are followed by a flash-off area where the solvents are evaporated. The ventilation and control of airstreams, temperatures and humidity are always of crucial importance to the final painting result.
After flash-off, the paint is dried in a direct gas-fired convection oven. More than 50 years of experience allow Moldow to carefully design highly reliable and efficient ovens that provide optimum temperature accuracy. After the drying oven, the items are cooled down before being ready for inspection and unloading.
Recirculation has been included to ensure energy optimized operation with reuse of the heat. The ventilation system ensure a balanced air extraction and supply in relation to the surrounding factory premises. Designed with noise reduction wall for a better working environtment.
