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ADVANCED SOLUTIONS IN PAINT COATINGS
Advanced solutions in paint coatings
Introduction BENITO’s long history and experience in painting has enabled it to develop its own way of working, oriented towards quality and customer service while meeting environmental demands at all times. The fact that we are manufacturers obliges us to take care over every single detail from beginning
DESIGN
to end of the process. Sensitivity to colour and texture together with professional rigour and efficiency have made us a benchmark in the field of industrial painting and a driver of innovation within the surface treatment sector. Anticorrosion treatments are among the primary concerns of our quality department. For this reason we have more than 6,500 square metres of facilities equipped with the latest coating technology (both for industrialised processes using powder paints and for more traditional ones using liquid paint). BENITO has various paint lines and a flexible, environment-friendly industrial structure designed 100% to optimise processes and resources.
QUALITY
A comprehensive, efficient structure which allows us to take on the widest possible range of orders, including those from industrial sectors which demand special preparations, high micronage, high-strength pieces or very delicate items.
INNOVATION
MANUFACTURING
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SURFACE TREATMENTS
Advanced solutions in paint coatings
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Facilities A latest-generation pain line
BENITO recently started up a latest-generation paint line at its new production plant. This line is specially designed for large, heavy pieces and allows powder coating of pieces up to 7 metres long and weighing 1,000kg. This facility is the only one of its kind in Spain, with a length of 980 metres and taking up 2,000 square metres of floor space.
BENITO has a new powder coating line for large and heavy pieces.
Close to the two paint lines the company currently runs, BENITO has installed two fully computerised storage towers to facilitate access to and monitoring of paint stocks, as well as making it possible to store materials under ideal temperature and humidity conditions. The proximity of these smart paint storage towers to the test laboratory also facilitates technical analysis of the paint before beginning the production process.
Smart paint store on the BENITO site.
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Advanced solutions in paint coatings
New powder coating line High capacity
Better results
The line allows pieces up to 7m long weighing 1,000kg to be
At the exit from the application area, the conveyor line enters
coated.
the infra-red gelling tunnel and the surface temperature of the pieces rises rapidly, gelling the powder applied.
Flexibility: twin-rail conveyor (Power & Free)
This process avoids subsequent loss of paint, prevents
The twin-rail conveyor allows each frame to be set up for a
contamination between frames coming from the two
different, specific cycle.
application booths and guarantees a better end result.
The fully automated process is controlled by the programme according to the information linked electronically to each frame. In this way the best use can always be made of the resources
Better working conditions
available and the booth distribution.
From a productivity point of view, the three loading units (and two unloading units) enable operators to work under the best
When the work programme calls for it, the electronic conveyor
possible conditions regardless of the size of the pieces, which
management system takes the frame to the waiting area and
are always loaded with the frame stationary.
then into the pre-treatment tunnel or application area. The fitting of lifting systems also makes the job of loading and unloading easier in the case of heavy pieces.
Versatility: two paint application booths The incorporation of two booths (designed by Wagner) makes it possible to work with different colours and rhythms. A total of 4 oscillators and 28 automatic spray guns are fitted, plus 4 manual guns, all with corona charge. The frames for pieces are distributed according to a coded programme, by means of rail switching, to booth 1 (used for the main colour) or booth 2 (characterised by shorter colour change times).
The Power & Free twin-rail conveyor is able to handle the frames independently. It is built to work with very heavy loads.
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Inside the IR tunnel, where the powder is gelled. This phase prevents contamination between the frames coming from the two application booths. The cycle begins in the pre-treatment tunnel with a thorough degreasing and ends with final drying.
After the pre-treatment phase, the pieces pass through a large booth for the application, if required, of liquid products (wash primer or other base preparation products).
The installation works with absolute filters to prevent any emissions of paint to the outside.
The lifting systems ensure proper care of the pieces during handling and make the operators’ job easier.
New powder coating line Entrance to the polymerisation oven. Next to the IR tunnel are the structures of the final absolute filters, connected to the air/dust separation cyclones on the overspray recovery circuit.
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Advanced solutions in paint coatings
Quality System for monitoring and verifying pieces Technical monitoring BENITO has two test laboratories equipped with all the measuring apparatus necessary to verify proper finishing of the pieces during the process or at the end. This guarantees that the pieces will work perfectly and last a long time in the future.
Colour monitoring Micronage Shine Density of the paint Adherence Impact resistance Torsional resistance Drawing
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Treatments Advanced pain solutions
Main treatements Depending on the type of metal and its subsequent use, BENITO assesses and carries out the most suitable type of paint treatment:
Base treatment with shot blasting Special highly anti-corrosive treatment
HIGHLY ANTI-CORROSIVE TREATMENT
BASE TREATMENT (NO SHOT BLASTING) TREATMENT SEQUENCE
TREATMENT SEQUENCE
Shot blasting Degreasing Rinsing Phosphating Passivation (chromic or non-chromic) Rinsing in demineralised water Drying Painting
Shot blasting and/or degreasing Rinsing Passivation (chromic or non-chromic) Rinsing in demineralised water Drying Zinc-rich primer Painting and polymerisation
TYPE OF METAL
TYPE OF METAL Clean mild steel Pre-treated steel Steel with iron phosphate
Hot rolled steel
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Advanced solutions in paint coatings
1. Base treatment (no shot blasting)
Description Shot-blasting, or cleaning by propelling abrasive material against the surface, is simply a way of working cold. Compression forces are induced in the exposed surface layer of the metal objects by the impact of a stream of shot directed at the surface of the metal at high speed under controlled conditions. Another advantage, which was its primary function, is that it increases fatigue strength.
The process The process has other beneficial uses such as dissipating the tensile force which contributes to cracking, forming and consolidating metal parts and accepting adherence for any subsequent treatment of the parts. There are four grades of rust, the state of the surface before shot-blasting, and four grades of preparation of the surface depending on the rust grade (s 1, Sa 2, Sa 1/2 and Sa 3). These grades are regulated by the UNE-EN ISO 8501-1 standard and supplement, on the basis of which it can be stated that the grade of preparation carried out is A Sa 3. The shot used has a martensitic structure and a Rockwell hardness value of 40<HRC<51. The roughness values obtained are (depending on the quality of the material being shot blasted):
Ra-> from 5 to 9 micra Rz-> between 20 and 40 micra
General view of the hook shot blasting machine and detail of the centrifugal turbines.
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Rust grades on steel surfaces Before applying anti-corrosion paint to steel surfaces the surface is prepared in a particular way to ensure a durable finish. The preparation grade will be different in each specific case, and this is why four rust grades on steel surfaces and four preparation grades for these surfaces have been established. 1. Steel surface largely covered with a layer of adherent mill scale but little or no rust visible. 2. Steel surface with the beginnings of rust and from which the layer of mill scale is starting to flake off. 3. Steel surface where the layer of mill scale has disappeared due to corrosion or where the layer of mill scale comes off when scraped, but in which no large visible cavities have formed. 4. Steel surface where the layer of mill scale has disappeared due to corrosion and where large visible cavities have formed.
Effect on the product of the shot blasting process.
Preparation grades 1. Light shot blasting Loose mill scale, rust, coatings and foreign particles are removed. The appearance must match the figures for Sa 1.
Sa 1
2. In-depth shot blasting The whole layer of mill scale, rust and nearly all foreign particles are removed. Any residual contamination must be firmly adhered. The surface is then cleaned with a dust exhaust, clean dry compressed air or a clean brush. It must take on a greyish
Sa 2
colour and its appearance must match the figures for Sa 2.
3. Very in-depth shot blasting Layers of mill scale, rust and foreign particles are removed so completely that the remains are only visible as light stains or scratches. The surface is then cleaned with
Sa 2 1/2
a dust exhaust, clean dry compressed air or a clean brush. Its appearance must match the figures for Sa 2 1/2.
4. â&#x20AC;&#x153;Bare metalâ&#x20AC;? shot blasting The layer of mill scale, rust and foreign particles are removed completely. The surface is then cleaned with a dust exhaust, clean dry compressed air or a clean brush. Afterwards it must be a uniform metallic colour and match the figures for Sa 3.
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Sa 3
Advanced solutions in paint coatings
2. HIGHLY ANTI-CORROSIVE TREATMENT
The process
Description This powder coating process is used when the metal needs special
1. Shot blasting and/or degreasing
anti-corrosion protection features.
This phase uses shot blasting to remove all kinds of dirt from the It can be used on mild steel cleaned by shot blasting and on
metal: rust, mill scale, oil, grease or burnt grease, especially in the
pre-treated steel, though in the latter case there is a reduction in
case of welded pieces, for which a mechanical treatment is
the anti-corrosion protection.
necessary to remove the films of rust (see further details of the shot blasting process in the section on base treatment).
Without cleaning by shot blasting, it can be used on ferric phosphated steel (for best results, chromate passivation and rinsing
2. Priming with zinc-rich powder – Ferrus
with demineralised water is recommended).
In this phase a primer using epoxy powder with a high active zinc content is applied to the metal. This combined system offers greater
BENITO is the first Ferrus user approved in Spain to use this
anti-corrosion protection in aggressive environments and high
advanced anti-corrosion process as a result of which the metal
durability outdoors.
can withstand more than 1,000 hours in the saline mist chamber
The primer consists of a system of double-layer powder which is
according to the ISO 9227 standard.
applied in two stages:
Stage 1 Ferrus primer Baking at 200ºC MT Stage 2 Coat of Ferrus polyester finish Baking at 200ºC MT
3. Painting After the zinc-rich primer the powder paint coating is applied. This has a double function: appearance and protection.
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Tests conducted with the Ferrus anti-corrosion system
Sprayed with neutral salt (ISO 9227). With and without marking
MAIN ADVANTAGES OF TOTAL SOLUTION IN POWDER COMPARED TO LIQUID PRIMERS:
Result: over 1,000 hours with no loss of adhesion Natural exposure. Volvo SCAB corrosion test. With marking.
No solvent emissions A more environment-friendly process
Result: excellent behaviour under 24 months exposure on a marking panel and excellent edge protection
Faster processing times Ferrus after shot blasting, Sa 2.5 Ra 6-7 micra SCAB test. 24
Eliminates the liquid painting process
monthsâ&#x20AC;&#x2122; forced outdoor exposure.
Makes best use of the facility Shot blasting + D3 polyester
Shot blasting Ferrus + D36 polyester
Shot blasting Ferrus D36 polyester
To achieve the best possible results on each product the most suitable treatment is sought for the substrate (iron, cast, wood, plastic, etc.). Depending on this, BENITO seeks zinc-based epoxy primers or those with other new bases brought onto the market by the top names (Akzo Nobel, Dupont and Adapta). These provide the best guarantee in terms of both pre-treatment and final coatings or finishes. Our aim is to provide solutions to problems, with the best liquid and powder applications, not only to protect against vandalism but also anti-adhesive, anti-poster and anti-graffiti.
24 monthsâ&#x20AC;&#x2122; reinforced natural exposure TA about 4km from the sea Sprayed with saline solution (twice a week)
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Advanced solutions in paint coatings
Quality certificates Guaranteed reliability Thanks to its rigorous production system, BENITO holds ISO 9001/2000 certification for powder painting of metal parts and is the first Spanish user of Ferrus high anti-corrosion finishes. BENITOâ&#x20AC;&#x2122;s new paint plant is also highly environment-friendly, as it works with absolute filters which prevent any emissions of paint to the outside, so caring for the environment.
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