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
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.
Enameling furnace with Power & Free conveyor
DTC may assist with the evaluation, which solution is most suitable for your vitreous enameling project.
The US Department of Energy is enforcing a new testing protocol and a different metric for energy efficiency
The US Department of Energy has updated its testing and labeling standards for residential water heaters, replacing Energy Factor (EF) with a new metric called the Uniform Energy Factor (UEF).
Manufacturers say there’s nothing different about their water heaters, only the way the government requires performance data to be collected and reported.
Consumers shopping for a hot water heater by using the familiar yellow Energy Guides will see more detailed information than in the past.
Read more at
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.
Continue reading “Offline powder enameling plant for boilers”
Welcome to our homepage for (future) enamelers of water heaters, hot water tanks and boilers.
Perhaps the following topics are interesting for you :
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.
Continue reading “Enameling plant for electrical water heaters”
What is a porcelain enamel coating ?
Porcelain enamel is a durable glass alike coating, which is fused on a metal substrate.
More >> How about corrosion resistance ?
Studies showed that the expected lifetime of enameled boilers is much longer then alternative coatings.
More >> Is our tank suitable for powder enameling ?
Tanks should be made of mild steel, which is suitable for enameling, and constructed in accordance with ISO 4753-3.
More >> What type of equipment is required ?
A boiler enameling plant has typically three process steps; metal pretreament, enamel application and firing.
More >> How much cost a boiler enameling plant?
The required capital investment for a modern boiler enameling plant depends on a variety of aspects.
More >> How can DTC assist ?
DTC may provide independent advice & support during all stages of your enameling plant project.
Porcelain enamel provide a robust “glass-lining” to warm water tanks to protection them against corrosion caused by boiling water and is therefore used by leading manufacturers of electrical boilers, solar water heaters and/or other warm water containing applications.
Enameled mild steel tanks are typically used to eliminate expensive water tanks, made of copper and/or stainless steel, which are less suitable for operation in area’s with “poor water”.
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.
Hot water tanks, which are typically used for (solar) boilers and water heaters, may be manufactured from either stainless steel, copper or mild steel.
The selection of the appropriate substrate depends on many factors, such as the annual production volume, the average dimensions of the tanks, expected water quality, desired product life and raw material cost.
Due to the ongoing price increases of stainless steel & copper, there is nowadays a worldwide trend towards manufacturing hot water tanks from mild steel.
HWT’s made of mild steel need to be coated internally, either with zinc, powder coating, nylon or enamel to protect it against corrosion.
According to a publication by the CISP, in which the various corrosion protection methods were compared, porcelain enamel provide the best protection (read longest life) against corrosion by boiling water.
Continue reading “Introduction to boiler enameling technology”