EcoSupply P: Minimum paint loss through piggable paint supply systems
Bietigheim-Bissingen, May 2015 – The number of paints used in automotive paint booths has multiplied in recent years. In particular, manufacturers of utility vehicles and plastic paint shops used over 100 different paints and colors. A large number of paints calls for flexible and piggable special paint systems. EcoSupply P ensures efficient workflows: this paint supply system from Dürr has convinced an increasing number of customers thanks to low paint dispersion losses, reduced solvent consumption and very short color change times.
EcoSupply P is a standardized, modular paint supply system featuring pigging technology that can be deployed for water- and solvent-based paint applications. Owing to the increasing variety of paints and colors, not only are special and customer-specific paints applied with the aid of pigging systems, but also small series paints. This has become necessary because only a limited number of paint connections is available on a robot that can be connected to the paint feeder hoses. In a paint booth for different vehicle models or for installation parts produced for a number of customers, however, the number of paints and colors needed can soon exceed the maximum number of 36 paints.
Pigs are lubricated, cylindrical fittings. They are located in the paint hose, where they move the paint in the direction of the atomizer or to the paint container. After applying the paint, they press the residual paint almost completely out of the hoses. They are “pushed” by pressurized air.
Pig systems reduce the consumption of paint and solvents substantially. In view of rising paint prices in the field of special paints and colors, this represents an immense advantage. Accordingly, piggable special paint supply systems pay off on their investment cost very quickly.
The following parameters vary according to the number of robots to be connected: paint dispersion losses: 300 to 700 ml per color change; solvent consumption: 6,000 to 20,000 ml per color change; color change times have been reduced to 15 to 25 seconds per color change.
Dürr has different types of pigging systems in its portfolio for various application types, in which a paint recovery of almost up to 100% is possible:
Basic Main Pass System: a pigging hose is installed on each side of the paint booth. The connection to the robots is mostly not piggable.
Main Pass System: a pigging hose is installed on each side of the paint booth. The connection to the robots is mostly by piggable means.
Single Pass System: each robot is connected to a separate pigging hose. This makes it possible to assign only the required amount of paint to the robot for the painting process. In view of the rising number of special colors and paints, this is becoming increasingly important.
To supply the pigging systems with paint, paint supply stations that can be changed quickly are necessary: The new paint supply station of the EcoSupply P consists of a substantially lower number of construction parts than the fully automatic paint cabinet and therefore is considerably more favorably priced. This structure facilitates faster commissioning and simplifies maintenance and services, with the key data on paint and solvent consumption being identically good.
A further strong point of the EcoSupply P system is its flexibility: its modular structure makes it possible to combine various paint supply units with a capacity ranging from 10 to 500 liters. A common variant is the 2-in-1 system: one supply container for 25 liters, one for 250 liters as well as an integrated stirring plant cleaning station. The customer can also use the 2-in-1 systems with identical container sizes to process special effect paints.
The new paint supply station has been used by Dürr since last year – meanwhile at various locations in Europe and South America. Customers order them both for new paint shops and for facilities to be converted.
This represents the continuation of a success story: in 1999, Dürr commissioned the first special paint supply system at Volvo in Umea (Sweden). Over 370 systems have since been installed.
At present, Dürr has developed a new, universal pigging target station that is even smaller and less complex, ensuring even lower paint dispersion losses within the robot, namely about five milliliters instead of 20 to 40 milliliters per color change. This pigging station will be used for the first time in the production of a transporter in Europe.