Symach S.r.l. Via Bazzane, 69 Calderara di Reno 40012 Bologna - Italy
www.symach.com info@symach.com
Phone +39 (0)51 963161
DRYTRONIC TECHNOLOGY & SYMACH PAINT PROCESS
TABLE OF CONTENTS Drytronic Technology 4
1. Infrared
4
1.2
Infrared is part of electromagnetic waves spectrum
5
1.3
The paint molecules
5
1.4 Drytronic
6
Symach Paint Process "SPP"
7
2.
8
2.1 Primer
9
2.2 Waterborne
10
2.2
11
Conclusion and Advantages
Body Filler
Clear lacquer
1. DRYTRONIC TECHNOLOGY 1.1 Infrared Symach has invented and patented a generator that operates based on a chemical reaction between hydrogen and oxygen (catalytic reaction), using natural gas or LPG (liquid propane gas). This chemical reaction generates different temperatures that produce a wave spectrum ideal for drying every paint including both waterborne and solvent-based paint. Chart 1 shows the comparison of drying times using Drytronic as well as traditional methods, including hot air oven and electric infrareds. Symach’s Drytronic technology allows paint to fully dry in less than one minute.
Chart 1
1.2 Infrared is part of electromagnetic waves spectrum The energy (heat) can be generated in three different ways: conduction by contact, convection by hot air and electromagnetic waves by infrared rays. The electromagnetic waves are both visible and non-visible and include: gamma rays, X rays, UV rays, visible light, infrared rays and radio waves. The infrared is part of the total spectrum and is divided by short, medium and long waves based on the length. When the shorter ones penetrate inside the molecules of paint, the longer ones remain outside. Every temperature can produce only one measurement of a wavelength. The electric infrared uses an incandescent filament of steel for medium waves and tungsten for short waves. Both can produce only one wavelength even if they are different.
drawing of wave length spectrum 4
1.3 The paint molecules Paint is a composition of various elements composed of different atoms. Every atom absorbs a different wavelength. In order to have an instantaneous absorption of infrared, the paint needs a spectrum of wavelength that consists of many different wavelengths.
drawing of a molecule of paint
1.4 Drytronic The Drytronic technology is a catalytic chemical reaction generated from hydrogen and oxygen using gas, methane or propane. A special filter of catalyst divides the molecules of gas in the hydrogen and carbon. Because carbon is not used in the Drytronic technology, there is no fire, no combustion and no emissions of carbon monoxide. The hydrogen from inside of the panel comes on the outside surface and merges with the oxygen that is in the air. When the hydrogen and out divided from the carbon oxygen merge, the result is a chemical reaction that generates heat. Symach’s patent permits the modification of the wavelength in order to reach every atom in the paint, In fact, Drytronic produces many different wavelengths at the same time, going inside the molecules of paint and activating instantaneous drying. This is due to every atom of paint receiving the correct wavelength. The Drytronic technology is used with a robot and its laser sensors, which automatically manages the variables for different absorption of infrared for different paint colours, different thicknesses, different parts of vehicles’ materials and different room temperatures. The Drytronic technology properly dries every type of paint no matter what the variable is. It only takes 50 seconds of exposition time to dry clear 100%; 30 seconds to dry waterborne; and 40 seconds for body filler and primer. The robot, which moves the panel of Drytronic technology, distributes radiation over the painted car, so every part of the car is dried in the same way with the same high quality. Drytronic technology is very cost-effective compared to the conventional oven method. In fact, the quantity of gas used for drying a painted car is no more than 10% of the amount used in a conventional spray booth.
drawing of panel section
See Drytronic technology in Symach’s video: https://youtu.be/Jow009JDp8E 5
2. SYMACH PAINT PROCESS "SPP" The Symach Paint Process "SPP" represents the proper painting method that integrates the application, the Drytronic technology and the robot. Since Drytronic allows paint to dry so quickly, the technology enabled Symach to develop a painting process that significantly reduces flash-off times and drying because the robot performs this process faster than a conventional booth or any electric infrared. Drytronic technology offers superior quality and quicker drying times compared to other processes involving the use of hot air ovens or electric infrared heaters. Furthermore, the painting product is chemically stable and inert. This prevents the appearance of any future defects, while at the same time allows for immediate polishing. The SPP application, the drying process and the Drytronic technology are compatible with all brands of paint and products including body filler, primer, water and solvent-base, and clear. The robot’s database uses certain formulas that enable the paint to dry properly using every product and brand of paint, without any defect. No changes are involved in respect to the paint producer’s datasheet, other than the sequences of application coats. The SPP application time compared to the conventional process is reduced by 60% to 70%, while the drying time using Drytronic technology and the robot is reduced by 80% to 90%, compared to using a conventional spray booth or electric infrared. The SPP is well presented in the videos on Symach’s website www.symach.com.
6
2.1 Body Filler The SPP for body filler is reduced to one application to complete the reparation, instead than two as in conventional process, this because the application is carried on with a process that include the hot support. This process for body filler reduces labor time of 50-60% compared the conventional process and the quality is superior in compactness also the drying is guaranteed to the 100% avoiding also every future defect in reduction of thickness. For example, the continuous and uninterrupted body filler application and drying, takes place in less than five minutes. See the body filler process in Symach’s video: https://youtu.be/LnfF0EEy7To
BODY FILLER - 2 PANELS REPAIR SYMACH PAINT PROCESS
1 MINUTE
FIRST BODY FILLER LIGHT LAYER
2 MINUTES
ROBOT CARRIED ON FLASH/OFF MAKES WARM UP SURFACE
CONVENTIONAL PROCESS
4 MINUTES
FIRST BODY FILLER APPLICATION
16 MINUTES
DRYING WITH ELECTRIC IR
3 MINUTES
FINAL BODY FILLER APPLICATION CARRIED ON WITH HOT SURFACE MULTIPLE LAYER IN ONE VISIT
3 MINUTES
FINAL DRYING
1 HOUR
FIRTST AND FINAL SANDING 30 MINUTES AVERAGE PER PANEL
1:20 HOURS
FIRST SANDING STAGE 40 MINUTES AVERAGE PER PANEL
4 MINUTES
SECOND BODY FILLER APPLICATION
16 MINUTES
DRYING WITH ELECTRIC IR
4 MINUTES
FINAL SANDING 20 MINUTES PER PANEL
TIME FOR APPLICATION AND DRYING 9 MINUTES. TOTAL TIME INCLUDING SANDING H 1:09
TIME FOR APPLICATION AND DRYING 40 MINUTES. TOTAL TIME INCLUDING SANDING H 2:40
7
2.2 Primer The SPP for the primer is carried out for the three coats in less than two minutes without interruption because the flash-off between coats is performed by the robot. This allows the use of roll primer and obtains the same performance as spray primer in thickness, orange pill and drying time. It also saves approximately 20 minutes or less per job in masking time and 60% in product because there is no overspray. The labour time in application is reduced 60 to 70%. For example, the application and drying of three coats of primer can be performed in less than eight minutes. See primer process in Symach’s video: https://youtu.be/tMjl-cu6ljM
PRIMER - 2 PANELS REPAIR SYMACH PAINT PROCESS
CONVENTIONAL PROCESS
1 MINUTE
THE FIRST COAT APPLICATION WIT T ROLL PRIMER OR SPRAY PRIMER USING SAME PROCESS
2 MINUTES
ROBOT CARRIED ON FLASH-OFF
1 MINUTE
THE SECOND COAT APPLICATION
2 MINUTES
ROBOT CARRIED ON FLASH-OFF
1 MINUTE
THE THIRD COAT APPLICATION
1 MINUTE
THE FIRST COAT APPLICATION
5 MINUTES
WAITING FLASH-OFF
1 MINUTE
THE SECOND COAT APPLICATION
5 MINUTES
WAITING FLASH-OFF
1 MINUTE
WAITING FLASH-OFF
24 MINUTES 2 MINUTES
FINAL ROBOT DRYING
40 MINUTES
FINAL SANDING 20 MINUTES PER PANEL AVERAGE
TIME FOR APPLICATION AND DRYING 9 MINUTES TOTAL TIME INCLUDING SANDING
49 MINUTES
8
DRYING 2 MOVING POSITION ELECTRIC IR
60 MINUTES
FINAL SANDING 30 MINUTES PER PANEL
TIME FOR APPLICATION AND DRYING 37 MINUTES TOTAL TIME INCLUDING SANDING
H 1:37
2.3 Waterborne In accordance with the paint producer’s datasheet, SPP uses two different processes for waterborne. The first one is executed by spraying the three coats in one visit without waiting or blowing between coats and then the robot is used for drying. The second one is executed by spraying the first two coats in one visit, similar to the first process. The robot is used for drying the two coats and then the drop coat is the final sprayed coat. For example, less than six minutes are required for application and drying of three painted panels. The labour time in application is reduced 70 to 80% compared to the conventional process, and the quality of drying allows the removal of dirt that drops during the application process so the quality of the final result is not comprised.
See waterborne and clear videos: Easydry: https://youtu.be/9FADxcTqfA4 - Robodry: https://youtu.be/10iBRQR-cUY
WATERBORNE - 3 PANELS REPAIR CONVENTIONAL PROCESS
SYMACH PAINT PROCESS 5 MINUTES
THREE COAT WATER BASE SPRAYING 3 COATS WITHOUT BLOWING
3-5 MINUTES
ROBOT DRYING
3 MINUTES
FIRST LIGHT COAT OF WATER BASE SPRAYING
12 MINUTES
DRYING WITH BLOWING
3 MINUTES
SECOND FULL COAT OF WATER BASE SPRAYING
18 MINUTES
DRYING WITH BLOWING
3 MINUTES
THE DROP COAT OF WATER BASE SPRAYING
6 MINUTES
BLOWING
TOTAL TIME APPLICATION AND DRYING
8-10 MINUTES
TOTAL TIME APPLICATION AND DRYING
45 MINUTES
9
2.4 Clear lacquer The SPP for clear is executed for the two coats in one visit without interruption for flash-off. For example, less than 12 minutes are required for application and drying time in order to paint three panels. The labour time saved compared to the conventional process is more than 60%.
See waterborne and clear videos: Easydry: https://youtu.be/9FADxcTqfA4 - Robodry: https://youtu.be/10iBRQR-cUY
CLEAR LACQUER - 3 PANELS REPAIR SYMACH PAINT PROCESS
4 MINUTES
2 COAT OF CLEAR SPRAYING IN ONE VISIT
10-12 MINUTES
ROBOT DRYING
CONVENTIONAL PROCESS
15 MINUTES
THE FIRST COAT OF CLEAR SPRAYING
5 MINUTES
WAITING FLASH-OFF
3 MINUTES
THE SECON COAT SPRAYING
30-40 MINUTES
DRYING
TOTAL TIME FOR APPLICATION AND DRYING
14-16 MINUTES
10
THE TOTAL TIME FOR APPLICATION AND DRYING
40-50 MINUTES
3. CONCLUSION AND ADVANTAGES Because Drytronic technology dries paint in less than one minute of exposition time, SPP also uses this technology for the flash-off phase. By being able to change the sequence of the paint coat application, there is no need for technicians to wait for flash-off, unlike electric infrared or hot air oven methods. SPP permits the preparator and painter to work on the reparation without interruption for flash-off and drying, saving more than 60% of the time spent applying the paint products, compared to the conventional process. The SPP and Drytronic technology help avoid every possible defect so it doesn’t appear in the paint during drying treatment or a few weeks later as can happen using a conventional spray booth. The quality of drying is 100% guaranteed using Drytronic technology. The paint products at the end of drying treatment are completely dried and the polishing phase can be executed immediately without taking hours of waiting time, which can typically happen using a conventional spray booth. The quality of paint gloss is superior because every single product, including body filler, primer, waterborne and clear, are fully dried and the final shining is 4-5 gloss points superior to a conventional spray booth. SPP gives technicians an easier way to work in the preparation and painting phases compared to current methods because the technology and the robots permit them to simplify the current painting process. In addition, training is simplified and additional skills aren’t required. The SPP and Drytronic technology use a specific drying formula by brand and type of paint. All of the formulas are loaded into the computer systems of Symach’s robots.
11