By investing in an innovative painting system, the Solingen-based automotive supplier BIA can now also offer painted surfaces from its own production. After intensive planning and investments of around 3.5 million euros, the customized and compact system has now gone into operation. "By entering the production of painted surfaces, we are responding to the demand on the automotive market, which also wants painted plastic components in addition to our galvanized real metal surfaces," explains Dr. Felix Heinzler, Head of BIA Development and Process Technology.
In addition to its tried-and-tested chrome components, automotive supplier BIA now also offers painted surfaces from its own production (here painted sample parts), andgreat flexibility was particularly important to the BIA developers when planning the painting system. "We succeeded in building a flexible and compact system that also enables efficient series production," emphasizes Dr. Heinzler. Thanks to the diverse possibilities at the Solingen site, BIA can now expand its expertise and open up new market segments as a supplier of electroplated and painted surfaces.
BIA relies on particularly innovative, resource-saving and environmentally friendly technologies for the plant. Process developer and Deputy Head of Development and Process Technology, Ullrich Gutgar, emphasizes that the plant operates completely wastewater-free and is virtually pollution-free thanks to air recirculation and regenerative afterburning.
In the production process, the surface is cleaned of the finest impurities with aCO2 snow jet before the painting process and then statically discharged in an "ionization lock". In addition, the absence of conventional conveyor technology significantly reduces the entry of foreign particles. The latest robot and axis technology in the painting area results in very high mobility of the application technology and the flexible achievement of painting positions and simultaneous component alignment. For example, rear-side painting can also be implemented without any problems. Overspray, i.e. excess paint particles, are always discharged downwards and deposited dry in special brushes. "A complex process with circulating air and filter technology as well as regenerative afterburning guarantee pollutant-free exhaust air," explains Gutgar with satisfaction.
Energy efficiency thanks to resource-saving technology is also the focus when drying the components. BIA has succeeded in creating an energy-efficient, compact solution with the construction of a tempered circular drying oven, which is also a technological innovation.
In future, up to 30 square meters of surface can be painted per hour. "We have also attached great importance to simple handling when converting the paint systems, so that we are particularly flexible here. In addition to series production, our focus with this first system is also on learning opportunities and diversity for our process development," concludes Ullrich Gutgar.
