Automatic enameling plant for water heaters

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.

Automatic transfer unit for large boilers
Automatic transfer unit for large boilers

Alternatively a so-called power & free conveyor system may be used.

This conveyor type consist of two conveyor tracks above each other.

Example of power and free conveyor

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.

Furnace with Power & Free conveyor
Enameling furnace with Power & Free conveyor

DTC may assist with the evaluation, which solution is most suitable for your vitreous enameling project.

 

 

 

Successful implementation of industrial enameling plant projects

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.

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Setting-up new enameling plants

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 :

Please don’t hesistate to contact us to discuss your project requirements.

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Modern boiler enameling plants based on powder technology

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.

Online shotblaster

powder application system

Automatic boiler transfer unit

boilers entering furnace



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.


Reduction of energy consumption at industrial enameling plants

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.