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Depending upon the annual production volume, it might be interesting to reduce labor cost by integrating all equipment of an enameling plant for water heaters and/or solar boilers.
Such integration may be done with traditional monorail conveyors in combination with automatic transfer devices, like on the picture below.
Alternatively a so-called power & free conveyor system may be used.
This conveyor type consist of two conveyor tracks above each other.
On the lower level free cars may run, while via the power chain at the upper level the free cars may be (dis)connected and transported.
Nowadays there are P+F systems, which thanks to a very special transfer system even include the transport of products within the enameling furnace.
DTC may assist with the evaluation, which solution is most suitable for your vitreous enameling project.
Successful implementation of any new industrial enameling plant requires :
• Enamelable products
• Appropriate enameling process(es)
• Reliable equipment with correct capacities & lowest Total Cost of Ownership
• Logical plant layout
• Well trained people
• Smart process & quality control
• Adequate project management
DTC may assist with know-how & hands-on support to accomplish your enameling plant project in time and within budget & specifications.
We assist companies worldwide with setting-up new enameling plants on time and within specifications & budget by providing the following services :
- Process & equipment knowledge
- Equipment tender specifications
- Project planning & management
- On-site support during start-up
- Staff education & training
Benefit from our experience
As you may see on our reference list, we have been involved in more than 50 projects within the enameling industry since 1984.
Below some examples of our projects :
- Successful implementation of industrial enameling plant projects
- Offline powder enameling plant for boilers
- Modern powder enameling plant for cookers
- Enameling plant for cooker components
- Enameling plant for electrical water heaters
Please don’t hesistate to contact us to discuss your project requirements.
In January 2003 Nordson Benelux B.V. delivered upon request by Senter together with a consortium of four other Dutch companies, a complete boiler enameling plant based on Ferro’s electrostatic dry powder enamel technology to Leov Company in Veles, Macedonia in order to replace their environmental unfriendly galvanizing process.
Conversion from traditional batch to continuous operated enameling plant
OEM had a classical batch operated wet enameling plant, which equipment was due for replacement.
Wished to explore latest process & equipment technology and considers the implementation of continuous operation and electrostatic powder application.
Case story about the definition & implementation of an industrial enameling plant for electrical water heaters
An OEM of electrical water heaters aimed to reduce the cost price of their products, while improving its lifetime.
Wished to switch the watertank substrate from copper to mild steel with porcelain enamel coating.
Boiler enameling plant layouts can be projected with either conveyorized or stand alone shortblasting & powder application equipment.
This conveyorized solution is called “online” and the other stand-alone solution “offline”.
See below the schematic plant layouts for both solutions. Please click on the thumbs to see the full size layouts.
Online boiler enameling plants are typically used for large production volumes of relative simple hot water tanks.
Its main benefit is a high level of integration, which eliminate the need for manual transfer between the various process stages.
Below some pictures of various online boiler enameling equipment, such as :
shotblaster / powder application / automatic transfer device / furnace.
Please click on the thumbs to see the full size pictures.
Offline solutions are typically chosen for relative low production volumes or
complex product shapes.
This solution is cheaper and is also suitable for boilers, which can’t be clamped in the centering system of an online solution.
Below some pictures of offline shotblaster & powder application. Please click on the thumbs to see the full size pictures.
Energy is usually the fourth biggest operational cost for an industrial enameling plant after respectively amortization of equipment, enamel consumption & labor cost.**
For this reason it is important to pay attention to the energy consumption of various enameling machines when purchasing new equipment and to consider investments in energy saving measures and/or heat recovery equipment for existing equipment.
Last-but-not-least it is important to keep your enameling equipment in a good condition by regular preventive maintenance and operation with the appropriate settings.
Below a short presentation about energy savings at industrial enameling plants
** In countries with relative low labor cost, energy might even be the third biggest enameling cost.