The Powder Painting actual picture (A) and virtual picture (B). Please observe the powder debris on the booth floor. You can see powder debris more clearly in the virtual picture (B)
Principle and Objective of Powder Recovery Unit
Every powder grain must not be wasted without benefit
The advantage of powder paint which make many factories turn out liquid coating to replace with powder coating because powder paint makes pollution lower liquid paint. Unlike the liquid paint that the paint which does not coat workpiece is wasted into the treatment process, the debris powder paint on the booth floor is the good condition and available return to re-use. Therefore, the powder recovery system is created for improving the performance of reusing powder paint.
The efficiency of powder recovery unit
Even though the powder paint can be reusable but if the recovery process is poor performance. The powder paint may damage and may adhere with humidity then it will not be reusable. Sometimes, the duration of the recovery process is too slow and impact to make the whole process be slowly. The high performance and more reliable recovery unit must solve all this problem.
Overview of Powder Recovery Process
Component Powder Extraction Belt System
1. Powder Center
2. Powder Extraction Belt
3. Powder Recovery Equipment
4. Stainless Steel Booth
5. Sieve Trolley
6. Peristaltic Conveyor System
Example from an automatic powder coating system
Diagram of automatic powder coating booth system is a good and clear example because it is presented easily about the benefit of this system and follow the requirement of efficient, less-consumption and reducing the duration. The general process of the recovery process are following as below;
The Powder from the powder center (1) is charged up in the gun by high voltage.
The powder which is sprayed past the object is either carried to the powder recovery unit (3) by the powder extraction belt (2) or removed directly from the booth (4) by the multi-cyclone or the filter system.
The powder collected and sieved in the sieve trolley (5) is then transported back to powder center (1) by the peristaltic conveyor (6) and transferred into the original powder container.
The procedure will return to step 1 after spraying powder into object.
The Powder recovery unit by WAGNER
Recovery System which provides more energy-saving and powder consumable
Many companies ask themselves how they can use less energy to reduce costs and protect the environment more. For powder coating, WAGNER has an excellent solution: the EEP (Energy Efficient Package) series with its potential savings of up to 40%
One of the biggest global trends is energy-saving. This also affects powder coating systems. Here, energy is needed directly in the form of electrical power, for example, to drive motors, and also indirectly in the form of compressed air.
Even in the past, WAGNER has used energy-efficient components and energy-optimized processes in its powder coating systems. They have a function, for example, which switches off the lifting devices in gaps, or only activates guns if a workpiece actually travels in front of it. This function is known as gap and height control. These savings may appear small, however, they add up to a significant sum at the end of the year.
Pipe conduit with EEP Concept
Minimized pressure loss in order to move powder on passage way
Pipe conduit with conventional type
The powder dust will be jam and will not flow easily
Cutting energy costs for powder coating by up to 40%
The biggest energy consumer in powder coating, however, remained the fan motor in the final filter, which still consumes up to 37 kW of power and more. Now, WAGNER has developed a comprehensive energy-saving concept for this fan motor and successfully implemented it in 2016 in the "EEP" mono-cyclone and final filter series. EEP stands for "Energy Efficiency Package".
In the EEP concept, two measures come together to reduce airflow resistance and therefore compressed air consumption: first is an optimized pipe conduit between the cabin and the cyclone, and second is a special air guide within the mono-cyclone. With this setup, a smaller motor is sufficient to generate the same volume of suction. In this way the EEP series is able to reduce energy costs by up to 40% overall.
Layout of recovery system under EEP concept
Highly efficient tubing
Highly efficient cyclone
Highly efficient final filter
EEP is the Patent pending status
The powder flow pattern under-recovery system by EEP Concept
Equipment under powder recovery system
The powder recovery system includes main equipment 2 units following as Cyclone and filter. Cyclone is the first stage of WAGNER recovery system which is the significant equipment because it is responsible for catch and reclaims powder dust back to the feeding system. WAGNER's Cyclone is built under the EEP concept so every cyclone unit is high performance and reliability to provide efficient performance.
The final stage of recovery system which confirms that the EEP concept is reliable and present the great performance. After filter takes responsibility to catch powder duct which leaks out from cyclone and storage all powder dust and reuse it. There have an advantage that there is not powder duct out of the system and make powder coating system free pollution for the environment.