Full order books quickly push companies that do manual powder coating to the limits of their capacities. One solution is to switch to automated applications. In addition to the powder booth, powder preparation, motion systems and guns, this includes an intelligent control system that is easy to install and operate. This saves time and ensures a high coating quality.
With the new SprayPackE automatic control unit, WAGNER has brought a solution onto the market that meets all these requirements. It controls up to 20 automatic guns and the motion systems in the powder booth. "Thanks to its integrated design and high user-friendliness, the SprayPackE offers an ideal introduction to automatic powder coating. Even outdated plants can be easily modernised," explains Michael Topp, Global Senior Product Portfolio Manager at WAGNER.
Sophisticated user guidance saves time and money
With the SprayPackE WAGNER replaces the PrimaTech-CCM control unit. Compared to its predecessor model, this new product scores above all through its simple operation. Instead of numerous individual components, it consists of a central control unit that can be used to control the entire powder coating system. This also sets it apart from other solutions on the market. For example, the powder quantity can be easily determined via a central touch screen - for all guns, in groups or individually. With comparable devices, the guns must be set individually via the corresponding control modules. This costs time - and money, as an example shows: While an operator needs around ten seconds to change the parameters with conventional controls, new settings can be made with the SprayPackE in just two seconds. With an average of four setting changes per hour, extrapolated on the basis of a conventional eight-hour day, this results in an efficiency gain of several thousand euros per year.
Material savings through intelligent gap and height control
Customers also benefit from WAGNER's automatic gap and height control. The gap control ensures that spraying only takes place when a workpiece is in front of the guns. The powder supply is switched off in the gaps. In addition, the innovative height control system, which previously only existed for larger WAGNER systems, is now optionally available for the entry-level model. Michael Topp explains: "The height control optimizes the coating of parts of different heights by switching off guns that would spray past the workpiece. This works via a continuous light bar at the entrance to the powder booth. Spaces in the workpiece, for example in window frames, are also omitted in this way." This creates maximum efficiency and minimizes powder consumption.
The guided colour change process makes operation even easier. An easy-to-understand step-by-step guide helps to avoid errors and, as a result, time-consuming reworking or downtimes. Furthermore, a maintenance counter records the operating hours per component and thus enables an optimal maintenance routine for a long service life of the control unit.
Entry into automated powder coating or upgrade of obsolete systems
The new automatic control unit is suitable for all industries. Be it for users who switch to automatic coating, but also for upgrading outdated coating systems. "Controls in older powder coating systems can be easily replaced by the SprayPackE," says Michael Topp. "In principle, the booth and powder supply unit can continue to be used without restriction, as can guns up to a certain age."