Powder Coating | Top Performance

Top Performance - Custom Office Furniture And School Furniture Manufacturer With OEM &OEM Service.

Powder Coating

Top Performance Powder Coating Line: Excellence in Craftsmanship, Quality in Every Detail

In terms of equipment layout, we have thoroughly considered the rationality of the process flow. From the loading area to the unloading area, the entire production line's equipment is arranged in the order of the process sequence, ensuring smooth material handling during processing. For instance, key equipment such as spray washing devices, immersion degreasing devices, powder spraying booths, and curing ovens are all strategically positioned for ease of operation and enhanced production efficiency.

The powder coating line is situated within our state-of-the-art manufacturing facility, meticulously designed to ensure smooth production flow and efficient space utilization.The powder coating line is situated within our state-of-the-art manufacturing facility, meticulously designed to ensure smooth production flow and efficient space utilization. From pre-treatment water-blowing and dust removal to the spraying stage, the entire process has been fully automated.

Process Flow and Parameters

Our coating line features a rigorous and scientific process flow, covering every step from loading the parts to unloading the finished products. Below is a detailed introduction to the process flow and parameters:

Pre-treatment Stage:

Loading (Rack Loading)

parts are manually placed on the conveyor chain, preparing for subsequent processing operations.

Pre-oil Removal

Utilizing a spray method, with a processing time of 60 seconds at room temperature, to remove oil stains from the part surface.

Main Oil Removal

Employing an immersion washing method, with a processing time of 180 seconds at room temperature, and the process also involves in-depth cleaning using an ultrasonic cleaner. to further remove oil stains from the part surface.

Wash 1

Combining both immersion and spray methods, each with a processing time of 30 seconds at room temperature, to remove degreasing agents and clean dirt.

Surface Adjustment

An immersion treatment for 30 seconds at room temperature, to prepare for phosphating and enhance the phosphating layer's adsorption capability.

Phosphating

An immersion treatment for 180 seconds at room temperature, to form a phosphating layer that protects the part from rusting and improves coating adhesion.

Water Wash 2

Similar to Wash 1, combining both immersion and spray methods, each with a processing time of 30 seconds at room temperature, to remove residual phosphating solution and dirt not cleaned in previous processes.

Pure Water Wash 1

A spray treatment for 30 seconds at room temperature, to further remove impurity ions and ensure the part surface reaches a highly clean state before coating.

Pure Water Wash 2

A spray treatment for 30 seconds at room temperature, to further ensure the cleanliness of the part surface.

Blowing Water

A combination of automatic and manual blowing methods, with automatic blowing lasting 10 seconds at room temperature, to remove moisture from the part surface in preparation for subsequent coating operations.

Dripping Water

parts naturally drip water for 6 minutes on the conveyor chain at room temperature, to further remove surface moisture.

Water Cutting Furnace

A treatment for 15 minutes, with a temperature range of room temperature to 180°C, using a 500,000 kcal burner, to remove moisture and impurities from the part surface.

Cooling

parts naturally cool for 8 minutes in the cooling area at room temperature, to ensure the part temperature is suitable for coating.

Coating Stage:

Surface Dust Removal

Utilizing two advanced robotic arms, each equipped with an electrostatic dusting gun, the system meticulously removes dust particles from the surface of the workpieces, ensuring a thorough and precise cleaning process.

A Spray Booth (Spraying Powder - A Booth)

Equipped with Switzerland GEMA reciprocating machines and robotic touch-up systems for pre- and post-coating, as well as a backpack dust collection system, combining manual and automatic powder spraying operations.

B Spray Booth (Spraying Powder - B Booth)

Employing a cyclone spray booth, similarly equipped with Swiss GEMA reciprocating machines and front/back supplementary spray devices, as well as a canister powder recovery system, enabling quick line changes and improved production efficiency.

Curing Furnace

A treatment for 18.5 minutes, with a temperature range of room temperature to 220°C, using a 1,000,000 kcal burner fueled by natural gas, to cure the coating and form a durable and aesthetically pleasing surface.

Cooling

parts naturally cool for 13 minutes in the cooling area at room temperature, to ensure the coating is fully cured and reaches a temperature suitable for unloading.

Unloading

parts are manually unloaded from the conveyor chain, completing the entire coating process.

Production Line Features

High Efficiency

· Line Speed: The powder spraying line operates at a speed of 6 meters per minute, adjustable between 3 - 8 meters per minute to maximize production efficiency according to actual production needs.

· Automation Equipment: Equipped with multiple automated robots, including.

· 1 automatic water-blowing robot.

· 20 Switzerland GEMA reciprocating precision spraying systems.

· 2 automatic dust-removal robots.

· 4 automatic powder-supplementing robots.

These significantly reduce manual operation time and labor intensity, enhancing production efficiency and product quality stability.

Flexibility

Hanging Method: Utilizing a double-point hanging method with an adjustable hanging pitch of 200mm, capable of accommodating parts of various sizes and weights.

Conveyor System: Employing a QXG-200 type chain with a single-point hanging weight capacity of 35kg, ensuring stability and safety during part conveyance.

The total length of the spraying line is approximately 590 meters, configured with dual drives, allowing flexible adjustments to the production line layout and operation according to production needs.

Environmental Protection

Water Washing Process: In the pre-treatment stage, multiple spray and immersion water washing processes are employed to ensure part surface cleanliness while reducing the use of chemical agents and minimizing environmental impact.

Exhaust Gas Treatment: Efficient exhaust gas treatment equipment is installed at powder spraying and curing furnace stages to ensure compliant emissions and meet environmental protection requirements.

Powder Recovery: The B spray booth features a canister powder recovery system, which recycles excess powder generated during spraying, reducing powder waste, lowering production costs, and decreasing environmental pollution.

Quality Assurance

· Advanced Equipment: The introduction of advanced equipment, such as Swiss GEMA reciprocating machines and cyclone spray booths, ensures uniform and consistent powder spraying, providing reliable coating quality.

· Strict Process Control: Each process step has clear parameters for time, temperature, and operation methods, ensuring the stability and repeatability of the entire coating process, thereby guaranteeing product quality stability.

· Professional Manual Operation: In critical steps such as loading, unloading, and some powder spraying operations, manual operation is combined to make flexible adjustments according to the actual conditions of the parts, further improving product quality.

Product Applications

The high-quality coated products produced by our coating line are widely used in various fields, including but not limited to:

Office Furniture

Providing aesthetically pleasing and durable surface coatings for office desks, tables and chairs, filing cabinets, and other types of office furniture, enhancing the overall quality and service life of the products.

Tubular Components

Applying coating treatments to various metal tubular components, not only enhancing their corrosion resistance but also customizing colors and appearances according to customer needs to meet the requirements of different application scenarios.

Other Accessories

Such as hardware accessories, mechanical parts, etc., through the coating process, improving their surface hardness, wear resistance, and corrosion resistance, while also giving the products a good appearance.

Future Outlook

We will continue to introduce advanced automation technologies and equipment to further enhance production efficiency and product quality. We will also increase our investment in environmental protection technology research and development, striving to reduce energy consumption and pollutant emissions in the production process to achieve sustainable development. Meanwhile, we will closely monitor market dynamics and customer needs, continuously expanding the application fields of coated products to provide more high-quality products and services to our customers.

Thank you for your interest in the Top Performance coating line! We are committed to providing high-quality products and services and look forward to collaborating with you!

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Quality Without Compromise. Innovation Without Limits.

Located in Thai Binh Province, Vietnam. As a professional OEM manufacturing base for the entire furniture industry chain, we provide customers with one-stop furniture solutions from R&D to finished products.

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Tel: +84 0273912912

Cellphone: +84 0399873522 / +86 13631130272

Whatsapp: +84 0399873522

Website: www.topperform.com

Email: sales@topperform.com

Address: Part of land plot CN-2, area A, Quynh Giao Industrial cluster, Quynh Giao commune, Quynh Phu district, Thai Binh province, Vietnam.