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DELTA PROCESS SYSTEMS


NEW DELTA POWDER COATING PLANT AT KOMFORT PROVIDES MAJOR EFFICIENCY AND ENERGY-SAVING BENEFITS


Komfort is one of the UK market leader’s in the design and manufacture of commercial glazed and solid partitioning, laminate, timber and veneered doors, movable walls and wall storage systems. The company has a policy of extensive ongoing investment in tooling and manufacturing facilities to ensure that it delivers cost-effective quality products that maintain its market position along with its high level of customer service.


As part of this policy, Komfort has recently replaced its existing powder coating facility at the company's Middlemore Road site in West Bromwich, with a new plant, designed and installed by Birmingham-based Delta Process Systems. The decision to replace the old plant followed an in-depth review to identify where important process enhance- ments could be made.


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Comments Paul Ward of Komfort: “A critical element of the new design, and a significant departure from the existing one, was the specification of a four stage pretreatment line and a high efficiency curing oven. The performance of all the integrated sections was specified to reduce the existing services footprint by 40%. The throughput of the new system had to accommodate an increase of 50% over the existing facility whilst guaranteeing a performance characteristic of 96%. The project team demanded high standards of materials and finish consistent with the qualities that they were familiar with from high grade European machine tool manufacturers, with whom they had a wide experience”.


The contract for the new facility was awarded to Delta Process Systems, which has extensive experience and proven technical expertise in this type of powder finishing project. Says Paul Ward:


“The result has been the design, manufacture and installation of a powder coating plant that is achieving all the specified targets, has the quality of build that is immediately apparent and has been commissioned with a conscientious level of support, enabling us to commit to full production three days ahead of schedule.”


The new plant embodies a number of special features, designed to maximise efficiency and save energy and materials. These include component light beam sensors in the pretreatment section to eliminate the situation of process pumps working unnecessarily when no components are on the line. Invertors are also fitted to the process pumps so that they can be adjusted to suit specified flow rates, and extended drain zones are included to eliminate contamination.


Another energy-saving feature of the new plant is the use of highly efficient oven air curtains, along with heat-capture hoods fitted to all oven entry and exits, which minimise heat loss through these large openings. In addition, ‘RW5’ insulation is used throughout to reduce heat losses through walls – this is of a much higher specification than generally employed in paint finishing systems.


The curing oven floors have also been insulated to improve heat retention and eliminate dust issues in the oven from the floor drying out. The oven has been designed to optimise the burner operation and guarantee a 100% cure without the


need to over-specify the burners. Oven airflow is adjustable to ensure an even and consistent temperature profile with no hot or cold spots.


Comments Bob Hughes of Delta Process Systems: “The plant was fully optimised at both the design and commissioning stages to ensure it runs at maximum efficiency – from both the energy cost and quality of finish points of view. The estimated annual savings over a typical powder plant of this size are over £12,000, which is obviously highly important with energy costs ever- increasing.”


Says Komfort's Paul Ward: “Our considered view is that we would not hesitate to specify Delta as a supplier to any of our manufac- turing sites and we would enthusiastically recommend them to our professional contacts – and have already done so, in fact. The entire Delta team is a credit to British industry and is an ideal example of the ‘partnered approach’ that is so often alluded to by many companies but seldom realised.”


For more information contact: Bob Hughes, Delta Process Systems Ltd, Old Walsall Road, Hamstead, Birmingham, B42 1EA. Tel: 0121 358 0606


Email: enquiries@deltaprocess.co.uk www.deltaprocess.co.uk www.komfort.com


Part of the new Delta Process Systems' powder coating plant at Komfort in Birmingham. The plant embodies a number of special features, designed to maximise efficiency and save energy and materials.


142 SURFACE WORLD september 2013 - show issue follow us on Twitter @surfaceworldmag


WE ARE EXHIBITING AT SURFACE WORLD 2013


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