Interlayer and topcoat
Interlayer is applied using Dynflow ® technology. It is a high-tech fully automated system for waterborne paint coating application. This technology thanks to the optimized conditions within the coating paint line (relative humidity of 85-90%, 20 g/m3 H2O/m3 of air) helps fully exploit the properties of paint. The result is an outstanding quality of the coatings archived with very low loss of varnish material.
Dynflow ® technology reduces deviation of paint spray pattern and increases its force, thus, paint drops reach all profile bends. Drops of paint whose viscosity is maintained almost at the same level are not subject to evaporation, and their mass and capacity practically do not decrease. As a result of very good properties of paint spreading with its increased thixotropy, Dynflow ® eliminates the need for further paint retouch work and sanding. The technology is ideally suited for painting complex details with corners and notches as the applied coating in these critical and very difficult areas is uniform.
Surface painting is also automated, and all through the use of electrostatic applicationsand recovery system Prolac. Electrostatic application is powered by high voltage of 100 kV/1 mA. Charging the paint particles with static electricity occurs in the tank and through electrode on the nozzle of the gun. The high degree of electrostatic charging of paint particles (e.g. 70 kV) drastically reduces overspray phenomenon. An additional effect is very good trim quality of the lacquered edges. Large material losses occurring in the traditional spray painting constitute additional burden for the the environment. With Prolac technology, the overspray paint can be collected, sorted and introduced back into circulation directly at the user. Rolling cylinders for collecting overspray are placed inside the spray booth between the lacquered part and filters to capture the post-painting mist. The spray guns are positioned in such a way that the jet is directed towards the cylinder. As a result, the overspray is collected continuously at the surface of the cylinder causing the full recovery of the paint.
To paint the most complex, unusual and longest components we use Fanuc painting robot controlled by Reiter systems. The robot adapts to a given component regardless of its size, shape and colour. All thanks to 3D scanners, cameras and advanced software. Scanners sweep the component body with lasers which are reflected on the surface and recorded by cameras. Then, by interpolation using a triangular mesh CAD 3D model is generated. The software analyses the model and "in flight" generates the kinematic software for the robot. This ensures extreme precision of application of individual paint layers, which translates into a perfectly uniform coating which far exceeds current market standards, where most of the producers paint windows manually using a gun. This significantly increases the durability of coatings, and thus, windows and doors themselves. The robot can also choose paint colours itself, and the change takes itless than 2 minutes.
Complete automation of paint processes also affects performance. The entire paint shop has been designed in such a way that none of cross beams carrying the window has ever stopped and constant feed speed of 3 meters per minute is maintained. Total monthly capacity of our paint shop is estimated at 27 000 m2, operating only at one shift. It is an amazing achievement considering the diversification of production.
It is worth mentioning that we use water-based paints that are safe for workers of the paint shop, final product users and the environment.