Therma-Tron-X, Inc.
Transcription
Therma-Tron-X, Inc.
SlideRail Square Transfer (SST) Electrocoating Systems Black acrylic primer is applied to flywheels and assorted small parts in baskets for a contract shop specializing in automotive coating. The SST system includes a roller conveyor for loading and unloading. High capacity electrocoating in a fraction of the floor space • 12-stage zinc phosphating pretreatment • 8’6” wide by 6’0” high by 4’6” long work envelope • 267 square feet per minute at 20 loads per hour • 4,000 lb. capacity per load A commercial lawn care equipment manufacturer employs this cathodic two color SST system to electrocoat sheet metal components and heavy steel frames with acrylic paint. • 15-stage zinc phosphating pretreatment • 9’0” wide by 6’0” high by 4’0” wide work envelope • 133 square feet per minute at 20 loads per hour • 1,000 lb. capacity per load This SST E-coat system applies a tough gray epoxy coating to blower and fan components. • 8-stage iron phosphating pretreatment • 9’0” wide by 5’0” high by 4’0” long work envelope • 133 square feet per minute at 20 loads per hour • 1,000 lb. capacity per load SlideRail Square TransferTM (SST) electrocoating systems from Therma-Tron-X are unlike any other equipment in the finishing business. Product indexes along a pair of low maintenance slide rails, rather than a traditional chain track. Because parts vertically enter and exit the process stages, SST systems provide electrocoating with complete immersion pretreatment in a fraction of the space required by monorail systems - and with greatly reduced tank charge costs. The SST concept permits the application of multiple processing alternatives through Programmable Logic Controller (PLC) load management. The PLC can supervise the simultaneous pretreatment of varied substrates and selectively electrocoat products in different color paint tanks. Automatic Voltage Control (AVC) adjusts applied voltage in the E-coat tank to match the square footage of the load, which prevents overcoating and saves both electricity and paint. The system may also be programmed to lengthen immersion time - ensuring proper coating thickness, even if a load exceeds the rated maximum square footage. This cathodic SST system electrocoats various carbon steel parts for a first tier automotive supplier based in Mexico. Stainless steel construction gives Therma-Tron-X SST systems long lasting durability. Multiple zone ovens include a dehydration section to minimize bleed-out, a cure zone and forced air cooling tunnel. SSTs may be equipped with an indexing carousel loop for stationary onloading and offloading of product, or directly linked by conveyor to fabrication, assembly and shipping areas of your plant to streamline your manufacturing process. ECON-E-COAT TM systems offer the same high throughput SST capabilities in a smaller work envelope with a more modest capital investment - and are shipped fully assembled and pre-tested. In fact, modular construction allows for rapid installation of any SST system. Plus, all Therma-Tron-X electrocoating systems may be equipped with complete water conditioning and wastewater treatment equipment from TTX Environmental. SlideRail Square Transfer systems are the perfect solution for electrocoating operations of any size SST E-Coat Options • Rack or Barrel Electrocoating • Multiple Color Capabilities • 11-stage zinc phosphating pretreatment • 9’6” wide by 5’0” high by 5’0” long work envelope • 252 square feet per minute at 20 loads per hour • 2,865 lb. capacity per load • Multiple Pretreatment Alternatives • Spray and Immersion Pretreatment Capabilities • Acid Clean with Iron Removal • Overhead and Side Transfer Cure Oven Configurations • Load Oscillation to Remove Trapped Air • Automatic Voltage Control (AVC) • Automatic Chemical Feeds • Automatic Startup • Complete Documentation Package for Process Information Analysis An SST ECON-E-COAT system applies black epoxy primer on assorted steel parts for a contract shop coater. • 11-stage zinc phosphating pretreatment • 5’0” wide by 2’0” high by 1’6” long work envelope • 17 square feet per minute at 20 loads per hour • 350 lb. capacity per load Monorail Electrocoating Systems Dependable design coupled with time-proven reliability Tool box components are given a bright red acrylic finish in this anodic electrocoating system. • 9-stage iron phosphating pretreatment • 2’6” wide by 5’0” high work envelope • 400 square feet per minute at 15 FPM Wheels for agricultural implements are coated with a white epoxy primer on this variable speed monorail E-coat system. • 7-stage iron phosphating pretreatment • 1’10” wide by 3’0” high work envelope • 94 square feet per minute at 12 to 20 FPM This monorail electrocoating system applies a tough epoxy primer to truck, trailer and farm implement wheels. • 6-stage iron phosphating pretreatment • 4’0” wide by 5’0” high work envelope • 144 square feet per minute at 10 FPM Years of research, experience and engineering innovation go into every Therma-Tron-X electrocoating system. Our reputation has been built on the success of our many satisfied customers throughout North America and overseas. TTX monorail E-coat systems feature SpiraFlowTM tank design which enhances paint circulation without clumping, settling or foaming. Solution spirals throughout the length of inclined, round bottomed tanks, ensuring that paint reaches and thoroughly covers every square inch of your parts - including those with complex configurations. Dead spots are virtually eliminated. Tanks may be specified with all stainless steel construction for longer life and lower maintenance costs. Phosphate stage heating by external plate and frame heat exchanger is available, and all stages are typically enclosed and exhausted to conserve energy costs and shield products from plant contamination. Conveyor deterioration is minimized by suspending parts through slotted roofs on process tank enclosures, protecting track and chain from corrosive atmospheres. Our “Current Collector” conveyor grounding mechanism eliminates mechanical adjustments necessary on other grounding systems. This exclusive TTX counterweighted design maintains excellent contact for a much longer period of time because it does not lose efficiency through wear. Therma-Tron-X electrocoating systems are managed by Programmable Logic Controller (PLC) hardware. System data such as tank levels, applied voltage and oven temperatures are monitored to ensure that all operating parameters remain within specifications. The PLC may be programmed for automatic system startup, automatic feed of bath chemicals and paint replenishment based on production levels, among many other options. It can also track loads of product through the system and interface with our optional documentation software, which downloads data for trending, graphing and process analysis. Other system options include varied pretreatment alternatives and multiple color capabilities. Pretreatment and postrinse stages are available in both spray and immersion configurations. ThermaTron-X has also supplied combination monorail systems which apply a powder or liquid topcoat over an E-coat primer. Conveyor integration with fabrication, assembly and shipping departments can assist in maximizing productivity. With Therma-Tron-X, you get the skill and knowhow of a world leader in electrocoating technology. This monorail electrocoating system applies a black epoxy primer on steel components for recreational vehicles. • 11-stage zinc phosphating pretreatment • 3’0” wide by 5’0” high work envelope • 200 square feet per minute at 12 FPM Shopping carts and various other wire products receive an epoxy primer in this monorail E-coat system. • 4-stage zinc phosphating addition to existing pretreatment system • 2’6” wide by 6’0” high work envelope • 60 square feet per minute at 8 FPM SlideRail Square Transfer (SST) Systems The versatile solution for industrial coating This SST powder system coats large weldments and other components for a maker of material handling equipment. • 7-stage zinc phosphating pretreatment • 15’6” wide by 6’0” high by 6’0” long work envelope • 3,600 lb. capacity per load A building components manufacturer with contract shop capabilities employs this SST powder system to coat steel and aluminum products. The system includes a programmed hoist for loading and unloading. • 14-stage pretreatment processes both steel and aluminum parts • 30’0” wide by 5’0” high by 1’6” long work envelope • 1,200 lb. capacity per load Scissors manlift components receive a tough, long lasting finish on this SST powder coating system. Parts undergo pretreatment and dryoff in one SST, are transferred to power & free conveyor for coating, and cured in a separate SST oven. • 8-stage iron phosphating pretreatment • 11’6” wide by 6’7” high by 3’0” long work envelope • 1,500 lb. capacity per load The SlideRail Square TransferTM (SST) material handling concept from Therma-Tron-X offers a combination of versatility and high throughput unmatched by other finishing conveyors. In addition to electrocoating, SST systems have been used in powder coating, heat processing and cleaning/ pretreatment operations with great success. In an SST, parts index along a pair of low maintenance slide rails, rather than a traditional conveyor track. Racks of product suspended from load bars are lowered into and raised out of all tanks simultaneously before moving to the next stages in unison. Because all loadbars are repositioned at the same time, SSTs produce significantly greater output than programmed hoists. Therma-Tron-X SST systems offer complete immersion processing in a fraction of the floor space required by monorail systems. Vertical product entry and exit allows each stage to be sized only slightly larger than the maximum work envelope - greatly reducing tank charge costs. An indexing carousel conveyor allows for stationary loading and unloading, and SST ovens permit close banking for greater capacity than other conveyorized ovens. Programmable Logic Controller (PLC) hardware monitors such data as tank levels and oven temperatures to ensure that all operating parameters remain within specifications. The PLC may be programmed for automatic startup and addition of bath chemicals based on production levels, among many other options. The PLC can also track loads of product through the SST and apply custom processing alternatives. Plus, our optional documentation software is able to download operating parameters for trending, graphing and analysis. SlideRail Square Transfer system technology is available only from Therma-Tron-X. The SST Advantage SlideRail Square Transfer systems offer a number of advantages over monorail systems of equal capacity. Among these are: Heavy weldments are powder coated in this SST system with integral dryoff oven and powder room. • 4-stage iron phosphating pretreatment • 16’0” wide by 2’8” high by 3’6” long work envelope • 3,000 lb. capacity per load • Maximum utilization of plant floor space • Modular construction for faster installation • Loading and unloading from stationary conveyor positions • Closer racking of parts for higher production throughput • Greatly reduced tank charge costs • Less water and chemical usage due to efficient utilization of multiple rinse stages • Lower maintenance and utilities costs This SST immersion cleaning and deoxidizing system treats windshield wiper head casings for a automotive tier supplier on the U.S./Mexico border. • 5-stage aluminum pretreatment • 5’0” wide by 2’0” high by 1’6” long work envelope • 200 lb. capacity per load Monorail Powder/Liquid Coating Systems Precision engineered to best meet your process requirements A manufacturer of major home appliances employs this 30 FPM monorail powder coating system to process upright and chest freezers. • 7-stage iron phosphating pretreatment • 3’0” wide by 6’2” high work envelope • 3,200 foot, 4-inch I-beam conveyor This 3 FPM powder system puts a corrosion and chemical resistant coating on processing machinery components for a manufacturer of paper industry equipment. • 4-stage iron phosphating pretreatment • 2’8” wide by 5’8” high work envelope • Enclosed track conveyor This 10 FPM monorail powder system applies a protective gray coating for a manufacturer of antenna dishes. • 7-stage zinc phosphating pretreatment • 2’0” wide by 4’6” high work envelope • Combination dryoff/cure oven with infrared preheat section • Enclosed track conveyor The design, manufacture and installation of complete coating systems has long been a Therma-Tron-X specialty. Our products have developed a reputation for dependability by reliably serving hundreds of customers in a wide range of industries. Therma-Tron-X engineers evaluate plant space, part configuration, coating requirements and throughput capacities before recommending the custom equipment and layout that best satisfies the needs of your finishing operation. Our experience in design, testing, fabrication and installation ensures that your system will provide maximum value with minimal investment. Therma-Tron-X spray washers deliver the optimal pretreatment combination of cleaning, conversion coating, sealing and rinsing stages for any painting process, and may be equipped with complete water conditioning and wastewater treatment capabilities from TTX Environmental. Spray and immersion configurations are available, with immersion tanks typically enclosed and exhausted to maintain temperature uniformity and shield parts from plant contamination. booths to allow external conveyor positioning - protecting parts from grease and dirt while preventing premature deterioration of track and chain. Dryoff and cure ovens feature high efficiency heat sources and fans offering precise performance throughout while pinching pennies in fuel and utilities consumption. Radiant heat sources are an option, as well as combination systems that use infrared vestibules to ramp up part temperature without disturbing powder coatings, followed by a conventional convection zone for curing. Therma-Tron-X supplies climate controlled environmental rooms, and works closely with application equipment suppliers to seamlessly integrate paint booths into any coating operation. Multi-function control panels keep all components operating smoothly and may be equipped with optional documentation software capable of downloading system data for process analysis. Conveyors of any capacity and complexity not only supply dependable material handling during the coating process, but can also help to streamline manufacturing as a whole by directly transferring product between fabrication areas, paint department and final assembly or shipping locations. Slotted roofs are standard in washers and spray Therma-Tron-X finishing systems stress efficiency and reliability from cleaning to curing. Automotive parts - primarily seating components - are coated by a contract shop using this 8 FPM powder system. • 6-stage iron phosphating pretreatment • 1’0” wide by 4’0” high work envelope • Enclosed track conveyor A contract shop coater processes assorted steel parts with this 10 FPM powder system. • 10-stage iron phosphating pretreatment • 5’0” wide by 5’0” high work envelope • 4-inch I-beam conveyor Combination Coating Lines Complete systems for efficient multiple coating operations Assorted aluminum products are processed in this 10 FPM monorail electrocoat/powder topcoat system employed by a contract shop. • • • • 8-stage aluminum pretreatment 2’10” wide by 4’4” high work envelope 150 square feet per minute Inverted enclosed track conveyor Electrical transformer tanks receive an epoxy primer and acrylic topcoat in this two-coat SST electrocoating system. • 8-stage zinc phosphating pretreatment • 12’0” wide by 5’0” high by 4’0” long work envelope • 150 square feet per minute at 17 loads per hour • 900 lb. capacity per load This SST electrocoating system with liquid topcoat serves a maker of truck utility bodies. Automatic load bunching allows simultaneous processing of single or multiple loadbars. • 8-stage zinc phosphating pretreatment • 22’6” wide by 10’0” high by 12’0” long work envelope • 200 square feet per minute at 12 to 15 loads per hour • Power and free conveyor transfers parts from multiple fabrication areas to the E-coat system and then to the topcoating booth Continuing public demand for high quality products means that manufacturers are turning more often to combination coatings to maximize the protective and attractive aspects of their finishes. These coatings begin with a premium pretreatment process for superior basecoat adhesion. Electrocoating is the preferred primer because of its allaround durability and corrosion resistance. A liquid or powder topcoat is then added for high gloss, endurance against fading due to UV exposure and quick color changes. Two-coat electrocoating systems apply a second E-coat layer over the primer for maximum protection against the elements. Therma-Tron-X finishing system construction matches the durability and reliability of these high performance coatings. We offer a wide range of material handling capabilities to meet every requirement of your operation. Our SlideRail Square Transfer TM (SST) systems have the advantage of total immersion pretreatment in a fraction of the floor space required by monorails. This SST system applies an E-coat primer and powder topcoat to steel and aluminum lighting products as large as thirty foot poles. SSTs may be programmed with a “rack bunching” option to handle differing size loads and multiple loads with peak efficiency. Larger parts enter the pretreatment/electrocoat system on a single carrier, while smaller parts may be grouped two or even three loadbars to a tank to maximize throughput. After the primer is cured, loadbars are ungrouped and banked before automatic transfer to the topcoating line. This ensures a steady stream of product racked with adequate density for efficient topcoating. Systems are monitored and managed by reliable PLC hardware, with optional documentation software able to download and analyze system data. ThermaTron-X also handles integration of topcoating booths and supplies environmental rooms for paint storage and spray coating operations. When a tough combination coating is essential, your best finish starts with a Therma-Tron-X paint system. Combination Paint Systems w Configuration Options w Conveyor Type SlideRail Square Transfer (SST) • 14-stage pretreatment simultaneously processes both steel and aluminum • 30’0” wide by 3’0” high by 2’0” long work envelope • 150 square feet per minute at 20 loads per hour • 1,000 lb. capacity per load • Power & free conveyor for powder application Monorail w Power & Free Inverted Power & Free Programmed Hoist Manual Transfer Pretreatment Zinc Phosphate Iron Phosphate w Aluminum Etch Prime Coat Epoxy E-Coat w Acrylic E-Coat Topcoat Acrylic E-Coat Powder w Liquid Spray An epoxy electrocoat primer and powder topcoat combination are applied by a contract shop coater to automotive luggage racks on this 9 FPM monorail system. • • • • 10-stage aluminum pretreatment 4’0” wide by 6’5” high work envelope 175 square feet per minute Inverted enclosed track conveyor Finishing System Components and Programmed Hoists Pretreatment Systems Conveyor Systems Thorough pretreatment assists greatly in corrosion resistance and paint adhesion - simplifying the coating process and improving the appearance of the product while adding years to its useful life. Optimum design and execution in the building of pretreatment systems is a Therma-Tron-X strength. Stainless steel washer construction permits the use of reverse osmosis or deionized rinse water, while slotted roofs protect conveyor components from corrosion and products from contamination. Our many years of experience enable us to engineer a system around your parts and your processes. Multiple counterflow technology greatly reduces water use and decreases solution dragout. Coupled with complete water conditioning and wastewater treatment from TTX Environmental, your ThermaTron-X pretreatment system will provide consistently clean parts with lower operating costs using fewer chemicals and less plant water while minimizing generated waste. Every Therma-Tron-X conveyor system is unique in configuration, load and process requirements. Our experience in the design, fabrication and installation of conveyors allows us to meet every challenge presented by the material handling aspects of your finishing process. Therma-Tron-X pretreatment systems maximize cleaning power through optimal design - including spray nozzle arrangements specific to parts and process. Therma-Tron-X conveyor systems satisfy any level of capacity and complexity through CAD-designed layouts that process products with superior efficiency. Industrial Ovens Most industrial processes require some application of heat. Our experience with a wide range of heating equipment and processes means that you can depend on Therma-Tron-X for a high efficiency oven system that meets or exceeds the specifications of your finishing operation. Conveyorized and batch designs are available with electric, oil, steam, gas or infrared heat sources. Our ovens feature aluminized steel interiors and exteriors with semi-rigid, non-settling mineral wool insulation. Blowers, fans and ductwork are sized for optimal air circulation, resulting in strict temperature tolerances throughout the entire oven. Heater boxes are assembled and tested in our plant prior to shipment. Therma-Tron-X also makes a variety of specialized heating apparatus: aluminum aging ovens, coil potting equipment, fluxers, palletizing shrink wrap ovens and baking and dehydration ovens for use in the food industry. You can count on our heat processing systems to provide the exacting performance demanded by today’s stringent manufacturing procedures. Reliable Therma-Tron-X conveyors are CAD-designed and PLC controlled for high capacity performance. Continuous monorail, power and free, inverted power and free, flat belt, roller type and chain-on-edge systems dependably automate any finishing operation, and may include transfer devices which readily link to existing plant conveyors. We design our equipment with maintenance in mind. Washers and paint application booths have slotted roofs to protect conveyor components from moisture that causes premature deterioration of track and chain, resulting in poor grounding and coating contamination. Conveyors are equipped with automatic lubrication and chain take-up systems to decrease wear, extend operational life and minimize downtime. Programmed Hoists Therma-Tron-X ovens are equipped with high efficiency burners and fuel modulation components to minimize operating costs while maximizing productivity. Therma-Tron-X multiple speed lift and travel hoists are capable of automating a wide range of finishing operations for businesses of any size. Programmed hoist systems from Therma-Tron-X are custom built to serve a wide variety of industrial finishing processes: rack or barrel electrocoating, dip coating, zinc or iron phosphating and alkaline cleaning. Our multiple speed lift and travel hoists are equipped with long lasting, high reliability components to handle the heaviest workloads and feature tanks built of durable stainless steel - unlike the plastic construction often used by other equipment manufacturers. Dependable PLC hardware monitors every aspect of the system. Loads may be run on a fixed recipe or random access basis. Radio frequency controls allow remote operation, and our laser positioning system ensures accurate high speed location of racks or barrels at each stage. Options include automatic control of chemical and paint feeds, auto shutdown/alarm management and process information downloading. Two or more hoists may be combined to maximize throughput, and may be interconnected with other plant areas to streamline production. Bulk loading and unloading equipment is also available from TTX. Water Treatment Equipment Therma-Tron-X Technology Optimizing the design of your system ... Custom systems built around your wastewater Wastewater treatment steps required by any company depends on the specific nature of their business. Engineers from TTX Environmental will evaluate your waste stream and recommend the best combination of physical and chemical treatment processes to bring your plant into compliance with federal, state and local discharge standards. At Therma-Tron-X, innovation has remained the driving force behind our continued success. Our technology, however, goes far beyond the use of computer aided design (CAD). We utilize software that performs virtual stress tests and deflection analysis on equipment components before the first drawings ever reach our shop floor. Other programs estimate dragout and determine rinse ratios to make our pretreatment systems as efficient as possible and calculate waste creation for correct sizing of wastewater treatment systems. Our wastewater treatment systems recycle cleaners, neutralize acids and alkalis, precipitate metals, detackify paints, clarify output water and concentrate solids for disposal. Sumpless collection systems can be operated on a batch or continuous basis, depending on volume. TTX has long been an industry pioneer in conveyor grounding and automatic voltage control (AVC). Our E-coat tanks ensure excellent circulation without foaming or settling, and our revolutionary SlideRail Square Transfer TM (SST) material handling concept maximizes throughput in minimal plant space. At Therma-Tron-X, we don’t just employ the latest technologies in finishing system design - we create them. Environmental efficiency is stressed through waste minimization and process bath reclamation to lower operational costs. Modular system components provide ease of installation and flexibility for future expansion in minimal floor space. Several TTX Environmental customers have received governmental awards for waste remediation in their plants. High quality water for high quality finishing Study after study has verified that the use of clean process water is essential to any finishing operation. This is especially true of critical areas like plating baths, electrocoating tank makeup and final pretreatment rinses. Water conditioning equipment from TTX Environmental meets the needs of our finishing system customers and other manufacturers for whom water with low total dissolved solids (TDS) plays an important role. Reverse osmosis (RO) conditioning systems are the finishing industry standard for production of clean water. Reverse osmosis provides low cost, low TDS water without hazardous chemicals and with no byproducts requiring treatment prior to discharge. When fed by an RO unit, a deionization (DI) system will supply ultra pure water at a reasonable per unit price. TTX Environmental also offers a wide range of water conditioning system components, including dealkalization units, water softeners, sand and ultraviolet filters, and degasifiers for CO2 removal. … and maximizing its performance To aid you in running your equipment at peak efficiency, Therma-Tron-X offers an optional documentation package which ties a personal computer to your system control panel. This computer software tracks system resources; records, stores and analyzes process variables; and suggests adjustments that may be made to help your equipment run at optimal levels. The program automatically downloads raw data which may be graphed or charted. It can be set up to calculate all costs involved in the finishing process, visualize alarm trends, track tank chemistries, monitor oven temperatures, calculate product through-put and determine cost per unit of finished product, among many other functions. If unsatisfactory parts are produced, system parameters can be retrieved from the period during which those parts were processed. Information may also be downloaded and sent electronically to Therma-Tron-X for remote engineering analysis. Operating manuals for Therma-Tron-X finishing systems are available on CD-ROM. Therma-Tron-X began manufacturing custom industrial ovens in the summer of 1971, and our original Sturgeon Bay facility was constructed in 1976. Since that time, our headquarters has expanded more than six-fold in response to ever increasing demand for our quality heat processing equipment, washers, programmed hoists, environmental products and complete paint systems. Because every product we make presents unique challenges in process, part configuration and space limitations, we must treat each of our customers on an individual basis. As a Therma-Tron-X client, you will receive a quote on the finishing equipment that best fits your operational requirements. Then we ask you, along with your chemical and paint suppliers and other vendors, to work with us every step of the way to ensure that the equipment we design, build and install meets your highest expectations. As a full service supplier, Therma-Tron-X handles every aspect of your purchase. We combine creative engineering, state-of-the-art computer design and hard working personnel to maximize the value of your system - meeting the needs of your business both today and well into the future. We take great pride in making things right. Therma-Tron-X, Inc. s Your best finish starts with us s 1155 S. Neenah Avenue • Sturgeon Bay, WI 54235-1996 Phone - 920/743-6568 • Fax - 920/743-5486 Website - www.therma-tron-x.com • E-mail - sales@ttxinc.com A subsidiary of Holdings, Inc.