GIARDINA GROUP automatic powder coating line

GIARDINA GROUP automatic powder coating line was built in 2018 in Italy by Giardina Finishing S.r.l. The line is characterised by a low level of wear, with a total operating time of approximately 6 months. During this period, it was used for coating panels intended for sectional doors.

The GIARDINA GROUP powder coating line was designed for the comprehensive powder coating of flat metal components with maximum dimensions of 6000 x 1300 mm. The entire process is performed continuously, without the need for manual handling of the components. Transportation of parts between the individual stages is performed using a conveyor system.

The system consists of:
– BR-6000 loading roller conveyor
– Dualtech 416 SB Dry automatic spraying machine
– electronic control system with a PLC controller and touch screen
– GPM/5 multi-level horizontal powder coating curing oven with hot air circulation and a Cleaning Box air purification station
– BR-6000 unloading roller conveyor
– NORDSON OptiMix 1 solvent and water-based paint application system
– two-chamber extraction system that allows hot air from both chambers to be directed straight into the hall without the need to discharge it outside

Powder coating takes place inside the GIARDINA GROUP Dualtech 416 SB Dry automatic spraying machine. The machine is equipped with two opposing reciprocating arms with four spray guns. This solution ensures an even coating of the entire surface of the workpiece, while reducing the spread of paint mist.

The arms are driven by synthetic toothed belts reinforced with steel wires. This enables precise adjustment of operating parameters, such as movement speed, acceleration and deceleration. Before entering the spraying zone, a measuring system automatically detects the dimensions of the components to be coated. The collected data is then used by the software to control the spray guns via ON/OFF signals. Their operation is adjusted to the size of the workpiece, which reduces paint consumption.

During spraying, the paint settles on the surface of the workpieces as well as on the conveyor belt. Any excess paint is captured by an extraction system located on both sides of the belt. The patented paint recovery system enables effective cleaning of the conveyor belt without the use of mechanical components that could cause wear. The cleaning process does not require solvents. Recovered paint is used to wet the surface of the belt. This allows it to be collected again without any change in viscosity or chemical properties. The compact design of the entire system reduces the cleaning agent consumption and minimises losses due to evaporation.

Once the paint application is complete, the coated parts are transported to the GIARDINA GROUP GPM/5 multi-level powder coating curing oven. Under the influence of high temperature, the applied coating is cured, providing it with the required mechanical properties and resistance to external factors. The components are stored inside the oven on conveyors driven by a high-performance motor and four pre-tensioned chains. Laminar air flow ensures uniform air distribution between the individual levels of the unit. The oven is also equipped with a Cleaning Box air purification station, designed to remove contaminants.

The GIARDINA GROUP automatic powder coating plant is controlled by an electronic control system based on a Schneider / Télèmecanique PLC controller and a 7-inch operator panel with a touchscreen. The control system has sufficient memory to store up to 50 user programs. The technological line also includes an extraction system and the NORDSON OptiMix 1 solvent and water-based paint application system, providing a complete solution for the automatic painting and coating of metal components.

Technical specifications of the GIARDINA GROUP automatic powder coating line

General data

• control system with keyboard, touch screen and Schneider / Télèmecanique PLC controller
• workpiece length: 300-6000 mm
• workpiece width: 100-1300 mm
• workpiece thickness: 4-60 mm
• operating speed: 2-6 m/min
• capacity: 120 m/h
• line dimensions (L x W x H): 25039 x 5063 x 3511 mm

BR-6000 roller conveyor

• quantity: 2
• length: 6000 mm
• roller diameter: 66 mm
• rollers covered with antistatic, solvent-resistant PVC with profiles protecting the space between the rollers
• feed speed adjustment: inverter
• height from floor: 870-930 mm
• height adjustment: manual
• control cabinet
• electrical installation protection degree: IP 55
• installed power: 0,37 kW
• dimensions (L x W x H): 6000 x 1690 x 900 mm
• weight: 600 kg

GIARDINA GROUP Dualtech 416 SB Dry automatic spraying machine

• 2 opposing reciprocating arms with 4 spray guns
• maximum working width: 1300 mm
• work table height: 870-930 mm
• feed speed: 0-120 m/min
• inlet roller conveyor L=1220 mm
• self-cleaning conveyor belt 2670×2000 mm inside the working area
• outlet conveyor belt L=1040 mm
• ambient air volume: 12000 m3/h
• fan power: 2x 0,37 kW
• extraction power: 7,5 kW
• inlet roller conveyor power: 0,18 kW
• conveyor belt power: 0,75 kW
• outlet conveyor belt power: 0,18 kW
• total installed power: 17 kW
• dimensions (L x W): 5000 x 3700 mm

GIARDINA GROUP GPM/5 multi-level horizontal powder coating curing oven

• internal machine width: 1400 mm
• maximum working width: 1320 mm
• maximum workpiece length: 2x 3000 mm or 6000 mm
• minimum workpiece length: 300 mm
• maximum recommended workpiece thickness: 60 mm
• conveyor belt L=6500 mm (5 pcs.)
• distance between conveyors: 90 mm
• maximum conveyor load: 115 kg
• work table height: 920 mm
• Cleaning Box air purification station
• supply air volume: 7000 m3/h
• fan power: 3 kW
• dimensions of the air supply opening: 670 x 1120 mm
• dimensions of the exhaust outlet opening: 280 x 280 mm
• total installed thermal power: 105000 kcal/h (122 kW)
• temperature difference range: 50°C (-10°C/+40°C)
• conveyor gearbox motor power: 0,75 kW
• total installed electrical power (level 3,4): 15 kW
• electrical installation protection degree: IP 55
• electrical cabinet dimensions (L x W x H): 800 x 600 x 2000 mm
• dimensions (L x W x H): 7700 x 3350 x 3350 mm

NORDSON OptiMix 1 solvent and water-based paint application system

• PLC controller
• 6 valve blocks for 6 colours
• dosing ratio: from 0,5:1 to 50:1
• mixing tolerance: ± 1%
• mixing capacity: 100-3000 cc/min
• medium viscosity: 20-5000 cps
• piston paint pump: SAMES KREMLIN Airless 40C100 (3 pcs.)
• automatic spray gun: SAMES KREMLIN Airmix (4 pcs.)
• paint pump stand
• maximum air pressure in the pneumatic system: 100 psi (7 bar)
• maximum medium pressure: 3625 psi (250 bar)
• maximum ambient temperature: 50°C
• maximum medium temperature: 80°C
• air connection: 1/4″ G (F)
• electrical installation protection degree: IP 55
• CE certificate
• control voltage: 24 V DC
• power supply: 230 V; 50-60 Hz

Two-chamber extraction system

• filtration system with 9 cartridge carbon filters
• maximum inlet and outlet connection diameter: 500 mm
• construction: 2 mm galvanised sheet metal