Industrial powder coating: Movingfluid for LPR

In this article:

• • • • The starting point: production (at least) unchanged in the smallest possible space  
      • The powder coating system for brake pads by Movingfluid  
      • The concrete benefits of the new plant: savings, flexibility and autonomy of management 
      • Simple solutions for complex problems

Industrial powder coating? The Movingfluid plant is compact, green and produces twice as much  

Maximum output and minimum footprint. In the industrial sector, these are the prerogatives of companies that want to innovate or renew their inventory: increase productivity, possibly by reducing the space occupied by the plant. And LPR S.r.l., specialising in the production of automotive braking systems, was no exception. Yet, when they approached us in 2021 to design a new powder coating system for their brake pads, we did not stop at the request: On the contrary, we played it like a poker game, when you have a full house of aces in your hand: we saw and raised. We also put a trio of extra benefits on the plate that the company did not let pass by: 

1. energy efficiency;
2. economic savings;
3. management and logistics autonomy. 

The starting point: production (at least) unchanged in the smallest possible space

LRP S.r.l.’s need was to replace the two old plants with just as many new ones that could guarantee at least the same amount of processed product (if not more) in the smallest possible space. This was not the first time the company had approached us: In 2007 and 2020 we had already built two brake disc coating plants for the Piacenza site: in this case, however, it was a pigment powder to be applied to pads, which is why, in addition to Movingfluid, other possible competitors were involved. But no competitor (not even those favoured by vertical experience in the industry) was able to stand comparison with the proposal put forward by our Problem solvers.   

The powder coating system for brake pads by Movingfluid

Our offer perfectly met the project requirements put forward by LPR S.r.l., who then awarded us the contract. In just 90 days from the assignment we built two twin installations tailored to their specific needs, starting with the overall dimensions: 10.4m long by 3m wide each. An extremely compact and functional size (a good 10m2 less than the solutions of the other partners!) also achieved thanks to some advanced technologies, such as infrared (IR) radiation ovens. This is how each structure is composed:  

1. The first station is for loading, where an operator places the pads on the conveyor belt; 
2. The pads move on to the coating area, an enclosed booth with two main elements: automatic spray guns and cyclone filter powder overspray collection and reuse; 
3. Unused powder is in fact recovered inside the filter unit connected and located a short distance from the plant: here it is screened and fed back into the system, thus reducing product waste; 
4. After coating, the parts enter the curing (oven) area where the 4 in-line modules, equipped with infrared (IR) emitters, ensure that the powder is cured; a special extraction system eliminates the fumes produced during the liquefaction and drying of the paint;  
5. The cooling, which is necessary so that the pads can be immediately handled by personnel upon leaving the plant, also avoiding possible dents (this takes place in the special station, named V8, because of its similar shape to a car engine);
6. After processing, the outgoing pads are collected in metal containers, ready to be picked up and subjected to subsequent operations (stamping, application of sensors, etc.);
7. The operator can control the entire process via an immediate and intuitive control panel with PLC.  

An innovative plant: the 4.0 tax credit

Movingfluid installations for LPR S.r.l. are designed to benefit from the 4.0 tax credit. This is a tax incentive designed to support Italian companies investing in new capital goods functional to the technological and digital transformation of production processes. Here are the characteristics that have allowed our installations to enjoy this incentive: 

1. CNC/PLC control: the capital good must have an automated control and management system, typically CNC (Computer Numerical Control) or PLC (Programmable Logic Controller) 
2. Interconnection: the machine must dialogue with the company’s IT systems (MES, ERP, WMS) to exchange data, instructions and part programs, often with remote loading; 
3. Simple human-machine interface (HMI): the interface must be intuitive and easy to use, to simplify operators’ work and improve efficiency; 
4. Compliance with safety, health and hygiene parameters: compliance with the latest occupational safety regulations; 
5. Remote maintenance, remote diagnostics or remote control; 
6. Continuous monitoring of work conditions and process parameters. 

An innovative plant: the IR ovens

The real innovation by Movingfluid are the infrared ovens, which are smaller than traditional solutions and therefore ideal in a context where every centimetre counts.  Unlike conventional convection ovens, IR technology does not use gas to produce heat, but cures paint by radiation using electricity. In this way, it eliminates the need for an environmentally harmful comburent (methane, which produces CO2) and contributes to the decarbonisation of the factory: less fossil fuels, more sustainability, in line with the latest market trends. And also more efficiency, since: 

1. The oven immediately reaches the desired temperature without preheating; 
2. Can be switched off when not in use and reactivated when needed with a single click; 
3. Radiation is concentrated only on the parts to be heated, avoiding energy waste.     

An innovative plant: the electrostatic system with triboelectric guns

In the absence of solvents and other adhesion substances, powder paint requires elecrostatic paint guns to make it adhere to the workpiece without dispersing into the environment. To do their job properly, brake pads need to be treated only partially: it is essential that the side in contact with the disc is not painted. Therefore, when they enter the coating line, they must remain lying on the conveyor belt (a position that exposes them to the Faraday cage effect, which repels powder). How to overcome this problem? With triboelectric guns: by moving the powder around inside them, they charge it electrostatically by friction and distribute the paint evenly over the entire exposed surface.  The homogeneity of the end result is also essential for this type of application, in order to avoid defects and ensure performance and durability of the part.  

The concrete benefits of the new plant: savings, flexibility and autonomy of management

As engineers and technical specialists, we have a soft spot for technology and its possible developments. However, our choices are motivated not only by professional interest and experimental nature, but by proven expertise and personalised assessments of each case. The solution proposed to LPR S.r.l. is characterised by at least 3 tangible benefits: savings, flexibility, autonomy of management. 

1. Savings: fewer staff and optimised consumption

First, let’s talk about savings, understood as both personnel costs and expenditure on energy resources. At the time of the request, the company employed its workers in three shifts to produce 2,400 pads per hour. Today, thanks to the intervention of Movingfluid, a single shift of 5 people is enough to achieve between 3,600 and 4,000 parts, with a peak production potential of more than 5,000 parts per hour. Essentially: we increased productivity while reducing the labour force needed to generate it.  Furthermore, of the four ovens on each plant, the company currently only needs to use three, leaving the fourth as a backup: so, in the unlikely event of a malfunction, it can avoid the risk of production stoppages. In this respect, although having higher energy supply costs, IR onevs reduce expenses and consumption. Compared to natural gas ovens, they can be switched on and off only when needed (gas ovens have to stay on all day), they reach the required temperature (180° C) in just a few seconds, and they concentrate the heat in a timely manner.  

2. Flexibility: layout adaptable to production needs

Another key aspect is the possibility of adapting the line to production requirements, both in terms of quantity and logistics. Both of these conditions are fulfilled by Movingfluid’s industrial coating plant, which, in addition to being able to handle larger or smaller volumes, can be easily taken down and reassembled inside the plant. Its block design allows it to be disassembled and relocated with the simple help of forklifts. An opportunity that LPR S.r.l. has taken full advantage of, having already moved it three times within the factory in response to new layout requirements that have emerged over time: all in complete autonomy. 

3. Autonomy of management: independent and simplified maintenance

This is indeed the additional quality of the structure: operation and maintenance can be carried out independently. One of the hallmarks of our relationships with companies is precisely the absence of commercial ties: We leave complete freedom to all the companies we collaborate with. In this specific case, for example, routine maintenance is elementary and is carried out directly by the company’s own personnel (previously trained by Movingfluid, which only supplies spare parts as required). In other situations, it may be advisable (but not compulsory) to activate an inspection or preventive maintenance service, which is always preferable to reactive maintenance as it anticipates possible criticalities and acts in time on the correct functioning of the entire system and its components.  

Simple solutions for complex problems

The functionality, also with a view to environmental sustainability, and the compactness of the systems designed by Movingfluid has won over the company, which, after more than 4 years of use, is considering doubling their size. This perspective confirms the reliability of the implemented solution that can be suitable for any use in industrial structural metalwork, even beyond OEMs (Original Equipment Manufacturers). In fact, we will never get tired of saying it, our Problem solvers have all the right cards (and a few aces up their sleeve) to easily solve any problem, even the most complex ones.    

Do you need to replace or upgrade your industrial painting system but doing so seems impossible? Let’s talk: solving the most difficult challenges is our job!

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