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ED Coating Plants
 

ED Coating Plants

CED PLANTS
Cathode Electro Deposition is most advanced and environment friendly Water based coating to be done on metal components. A combination of dip and spray ensures reach of paint at every corner of component having intrinsic shape as well. CED is chemically resistant, mechanically durable, and pleasant in appearance having very Good Salt Spray life and is sought for by all automobile users.
 
ED Coating Plants
CED bath (water filled)
CED bath (water filled)
Anode cell installed in ced bath CED bath (water filled)
without anode cell installed
CED bath (under filling)
with anode cells installed
     
 
 

ELECTRO - DEPOSITION COATING (ED COATING PLANTS)
Electro-deposition of primer coating has become universal for a modern automotive paint shop. In ED, charged particles from the paint emulsion move to Anode (AED) or Cathode (CED) under electrical forces. The direct current established through the bath makes the pigment and resin base of the paint wander towards the body surfaces. Coating reaches all the recessed area. Deposited film does not re-dissolve. However, the un-deposited material is rinsed. Ultra filtrate (UF) equipments are used for ED paint ingredients separation of those not forming film and recovery of Paints. Deposited film after stoving becomes hard, durable polymeric film.

 

E-COAT PROCESS

Customers today demand higher quality and durability from the products they buy. Not only do they expect these products to perform well, but they want the finish to look good and resist corrosion for a much longer period of time. This finishing processes is designed which is called as electro coating (E-coating).

E-coating is a method of painting which uses electrical current to deposit the paint. The process works on the principal of "Opposites Attract". This process is also known as Electro Deposition (ED).

The e-coat process can be divided into these four distinct zones:

  Pretreatment
  Electro coat Bath and Ancillary Equipment
  Post Rinses
  Bake Oven
 
 
ADVANTAGES OF ELECTRO - DEPOSITION OVER CONVENTIONAL PRIMER :
  Fully automatic operation, film thickness can be controlled.
  Uniform coating
  Better coverage in box and interior surfaces
  Good coverage of sharp corners
  No runs and sags
  No solvent boils
  Better chip and corrosion resistance
  Nearly 100% paint utilization.
  Superior in anti-pollution, safety, health hazards.
 
 
SPECIFICATIONS :
A) Number of stations in C E D baking oven 7
Oven operation Stop & go type
PT – CED PROCESS SCHEDULE 
ABBREVIATIONS: - TAL = TOTAL ALKALI, FAL = FREE ALKALI, TA = TOTAL ACIDITY, FA = FREE ACIDITY, ACC = ACCELERATOR CONTENT, EC = ELECTRICAL CONDUCTIVITY.
 
Sr. No. Stages Chemical Name Make up per 1000 LTR (Kgs) Testing Parameters Temp °C Time (sec.) Spray Press Kg. cm2 Remarks
1. Hot Water -- -- pH = 8.0 – 9.5 50 – 55 45 1.5 – 2.0 Frequent Renewal
2. K.O.Degrease
(Spray)
Nipaklin GN 4460 A
Nipaklin GN
4460 B1
4460 A = 20
4460 B1 = 12
F.AL. = 16 - 19 PTS 50 -55 60 1.5 – 2.0 } Permissible
} Oil Content
} in the in the
} = 4.0 G/L Max.
3. Degease (DIP) Nipaklin GN 4460 A
Nipaklin GN 4460 B1
4460 A = 20
4460 B1 = 12
F.AL. = 16 - 19 PTS 55 – 60 150 --
4. Water Rinse (Spray) Industrial Water --- Tal = Max .5.0 PTS R.T. 90 1.0 – 1.5 Continuous Overflow
5. Water Rinse II (DIP) Industrial Water --- TAL = MAX .3.0 PTS R.T. 45 -- CASCADE to WRI
6. Surface Conditioning
(DIP)
– X
Additive GN 4977
Additive GN 4977B
PL – X = 3
4977 = 0.6
Conc . = 2.6– 3.9
pH = 9 – 10 pts
R.T. 45 -- Discard Eevry 4 Months
7. Phosphate (DIP)
SS tank
Nipaphos GN
3020 M
Nipaphos GN 3020 R
AdditiveE GN 4813
Additive GN 4856
Neutraliser GN 4055
Nipacel GN 4704
3020 M = 48
3020 R = --
4813 = 5
4856 = 17
4055 = 8.6
4704 = 0.42
TA = 22 - 24 PTS
FA = 0.7 – 1.1 PTS
ACC = 2.0 – 4.0 PTS
40 – 45 120 -- Make up &
Replenish
Chemicals are
Different
8. Water Rinse III (Spray) MS FRP tank Industrial Water --- TA = MAX. 5.0 PTS RT 45 1.0 – 1.5 Continuous Overflow
9. Water Rinse IV (DIP)MS FRP tank Industrial Water --- TA = MAX. 3.0 PTS RT 45 -- CASCADE to W.R. III
10. DM Water Recirculate (DIP) MS FRP
Tank
DM Water --- pH = 6.5 – 7.5
EC < 30 μS/CM
RT 45 -- CASCADE to W.R. IV
11. DM Water Fresh (Spray) DM Water --- pH = 6.5 – 7.5
EC < 10 μS/CM
RT pass 0.8 –1.2 CASCADE to RCDM
 
 
ED PROCESS DETAILS :
 
 
Sr. No. Stage Temp. Process time Circulation Rate Chemical Temp Dosing system Material Cascading
1. ED tank 3 mins. 6~8 circulation turn overs/Hr by volume ED bath Paint 28 ~32 °C diaphragm pump for paint feeding MS tank with FRP lining, PVC piping in the tank, SS304 piping outside the tank. Eductor nozzles inside the tank for circulation Overflow of UF rinse I tank to ED tank by gravity or by pump other than spray pump
2. UF Rinse I spray 0.5 min. 0.5 ~1.5 Kg/cm2 spray pressure Re circulated UF permeate < 30°C (Provision for DI Water addition) MS tank with FRP lining, SS 304 piping & spray nozzles. Overflow of UF rinse II tank to UF rinse I tank
3. UF Rinse II Dip 0.5 min. 3~4 circulation turn overs/Hr by volume Re circulated UF permeate < 30°C (Provision for DI Water addition) MS tank with FRP lining, SS 304 piping, Eductor nozzles in side the tank for circulation Overflow of UF rinse III tank to UF rinse II by gravity or by pump other than spray pump
4. UF Rinse III spray 0.5 min. 0.5 ~1.5 Kg/cm2 spray pressure Re circulated UF permeate < 30°C (Provision for DI Water addition) MS tank with FRP lining, SS 304 piping & spray nozzles. Exit mist spray with fresh permeate. 10 lpm
5. RCDM dip rinse 0.5 min. 3~4 circulation turn overs/Hr by volume Re circulated DM Water Ambient (Provision for DI Water addition) MS tank with FRP lining, SS 304 piping, Eductor nozzles in side the tank for circulation Exit spray with fresh DI Water. 2 Lit/M2
6. Fresh DM Spray Pass time 0.5 ~1.5 Kg/cm2 spray pressure Fresh DM Water Ambient -- MS tank with FRP lining, SS 304 risers Cascade to RCDM
7. Flash off 5~10min --- --- Room Temp. --- --- 3 min flash off
8. Baking (30~40Min) --- --- 160°C/10 min. or 150°C/20 min EMT --- --- ---
 
 
 
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