Plastic spraying production program occupies a key position in the application of the door industry, especially for all kinds of door materials, in the surface treatment of steel doors, showing unparalleled advantages. Its excellence lies in the fact that under the current diversified market demand, whether it is a simple and stylish civil door, an industrial door with strict requirements on protection performance, or a high-end decorative door in pursuit of the ultimate aesthetic, the spraying production program can be perfectly adapted to the complexity and variability of the product design needs. The

spray solution is extremely flexible in its implementation, allowing key elements such as color, thickness and surface texture to be adjusted according to the design style and functional requirements of the door. With the help of the advanced intelligent spraying system, the operator inputs precise commands in the operation interface, and the equipment can quickly and accurately carry out a variety of complex spraying tasks. This highly automated mode of operation greatly reduces the over-reliance on workers' specialized skills. Even inexperienced novices, after a short period of professional training, can skillfully use the equipment and efficiently carry out plastic spraying operations. This not only effectively avoids product quality variations and defective products caused by human factors, but also strongly guarantees the stability and consistency of customized product quality. In addition, thanks to the convenience of plastic spraying production solutions in customized production, enterprises can quickly start the production process of diversified door products with low initial investment. Compared with the traditional painting method for different colors and effects of products need to frequently replace the paint and complex debugging, plastic spraying production program only need to replace the type of plastic powder and adjust the parameters of the equipment, which greatly saves the expensive material waste and debugging costs. This makes the enterprise in the introduction of plastic spraying equipment, capital pressure is greatly reduced, can be in a limited budget, quickly build up a strong customized production capacity of plastic spraying production line, timely response to the market demand for a variety of orders, help enterprises in the highly competitive door market to seize the first opportunity to achieve the prosperous development of the business and continue to climb.

Home Security Doors

Clean Doors

Medical Doors

Industrial Fire Doors

Fire Doors

(1) Spraying room: the powder is evenly sprayed onto the surface of the door frame/door by manual labor.

(2) Curing baking tunnel: through high temperature baking, make the powder coating melt, leveling, curing.

3）Workpiece offline: take down the cured door frame/door leaf for natural cooling.

4）Pre-treatment pool：Pass through the phosphating pool to remove the oil, dust and rust on the surface

5) Drying area: Phosphatized door frame/fan will be dried naturally.

6）Workpiece on the line: Hang the door frame/door to be sprayed on the conveyor line.

7）Pre-heating channel: remove the moisture on the surface of door frame/fan to increase the adhesion of plastic powder.

1）Workpiece on the line: robot will need to spray plastic door frame / door hanging on the conveyor line.

2）Pre-treatment：Automatic spraying to remove oil, dust and rust on the surface.

3）Pre-heating channel: remove the moisture on the surface of door frame/door, increase the adhesion of plastic powder.

4）Automatic spraying room: the automatic spraying system will evenly spray the powder onto the surface of door frame/door.

5) Curing baking tunnel: through high temperature baking, make the powder coating melt, leveling, curing.

6）Workpiece off the line: the robot will take down the cured door frame/door leaf for natural cooling.

Profit generating factors

Applicable structures

Preheating aisle

Curing aisle

Equipment investment

Employment requirements

Average daily production

Average wages

Equipment footprint

Turnover space

Probability of failure

Probability of scrap

Corporate image

Recommended Requirements

Automatic spraying

All structures are optional

35m

35m

1.5~2 million

1 person

≥300 gigs

5000~6000

500m²~600m²

100m²~180m²

low

low

Automation factory

Manual spraying

All structures optional

35m

35m

60~700,000

8 people

200-250 gigs

7000~8000

500m²~600m²

100m²~180m²

Low

Medium

Lean Manufacturing Plant

Manual spraying solution: small batch customized production.

Automatic spraying solution: batch customized production.

Phosphating tank / electric hoist

On the pieces: use electric hoist to lift the door plate and door frame smoothly, lifting them above the phosphating tank. Electric hoist has the function of lifting, lowering, horizontal movement, etc., can accurately control the position of the workpiece, and slowly put it into the phosphating tank on the hanging or bracket, to ensure that the workpiece is well fixed to facilitate the subsequent processing.

Lowering: After completing the phosphating treatment and water washing, the door plate and door frame will be lifted up smoothly from the phosphating pool by the electric hoist and transported to the designated area for subsequent treatment, such as drying and painting. In the whole process, the stable operation and precise positioning of the electric hoist ensures the smooth running of the pre-treatment process of door panels and frames, and improves the production efficiency and product quality.

Electric hoist is used in conjunction with the pre-treatment process

Enhance the coating bonding force: through the chemical and electrochemical reaction on the metal surface of the door plate and door frame, a layer of phosphate chemical conversion film, i.e. phosphate film is formed. This film can significantly enhance the subsequent coating film (such as paint, spray coating, etc.) and workpiece bonding, so that the coating is more firmly attached to the door and door frame, reducing the risk of coating off .

Enhance corrosion resistance: phosphating film can be isolated to a certain extent from the air, moisture and other corrosive media and metal substrate contact, effectively preventing the door and door frame corrosion, extend the service life of the door products.

Improve the decorative effect: after phosphating the surface of the workpiece, can make the color of the subsequent coating more uniform, full, improve the appearance of the door products decorative.

Phosphate pool role

Phosphating is a chemical and electrochemical reaction to form a phosphate chemical conversion film process, this layer of phosphate film can enhance the adhesion of the subsequent coating of the door frame door, but also to enhance its corrosion resistance. After phosphating the door frame door, the surface will be attached to the phosphate solution and other components, the need for natural drying to remove moisture, and let the phosphate film stable molding.

Staff will be phosphated door frame door carefully carried to a special drying area, which is usually well ventilated, free of dust pollution and avoid direct sunlight. During the natural drying process, the water gradually evaporates due to air circulation, while the phosphating film undergoes further physical and chemical changes, resulting in a denser and more stable structure. This link does not require additional energy heating, drying by natural conditions, but need to control the environmental humidity and temperature. Generally speaking, in the appropriate temperature and humidity environment (temperature 20 - 30 ℃, relative humidity 40 - 60%), natural drying time is about 2 - 4 hours. However, if the ambient humidity is high or the temperature is low, the drying time will be extended accordingly.

Drying area

Selection and preparation of hooks and conveyor lines

Hooks: generally made of stainless steel or carbon steel, should have enough strength and rigidity to withstand the weight of the door body and not deformed. Before use, carefully check the hooks, support parts have no wear and tear, fracture, there are problems in time to repair or replace. In order to ensure good contact between the door body and the hooks to prevent problems with the coating, the surface of the hooks should be clean, dry, no oil and rust, degreasing and descaling pre-treatment when necessary.

Conveyor line: Conveyor line is common chain, roller conveyor type and other types. When the door body is sprayed with plastic, it should be reasonably selected according to the size, weight and production scale of the door body. Before start-up, comprehensively check the chain, sprocket, motor and other mechanical transmission parts, add or replace the lubricant to ensure smooth transmission without abnormal sound. Calibrate the running speed of the conveyor line to ensure smooth and even movement of the door body. At the same time, check the electrical control system to ensure that the control buttons, sensors, etc., work properly, no short circuit, disconnection faults

Workpiece on the piece

Removing moisture from the surface of the door body: After washing and draining the door body after pre-treatment, moisture may still remain. When preheating, the temperature rises so that the moisture evaporates. If moisture remains, spraying will prevent the powder coating from adhering, causing bubbles, pinholes and other problems in the coating, affecting the quality and adhesion of the coating.

Improve the adhesion of powder coating: The suitable preheating temperature changes the metal lattice structure on the surface of the door body, enhances its surface activity, and prompts the resin and other components in the powder coating to form chemical bonds with the surface of the door body better after spraying, which greatly improves the adhesion between the powder coating and the door body, and ensures that the coating is not easy to come off in the long term.

Promote the leveling of powder coating: After the door body is preheated to a suitable temperature, the powder coating sprayed under the action of gravity and heat can flow more smoothly and spread, fill in the surface of the door body with minor bumps and fill in the coating is more flat and smooth, enhance the appearance of the door body decorative and protective properties.

Pre-heating oven

Electrostatic adsorption principle: Electrostatic spraying machine utilizes high-voltage electrostatic generator to form a strong electrostatic field at the head of the spray gun. When the powder coating is sprayed from the spray gun, it will rub with the electrode inside the spray gun, making the powder particles with negative charge. And the grounded door body serves as the positive pole, under the action of electrostatic field, the negatively charged powder coating will move quickly to the surface of the door body, thus realizing uniform adsorption.

Equipment inspection and commissioning: Before formal spraying, the electrostatic spraying machine needs to be fully inspected and commissioned. Check whether the gun head is clogged, if so, need to be cleaned in time to ensure that the powder coating can be sprayed smoothly. Test whether the electrostatic generator of the spray gun is working properly. At the same time, debug the powder supply system of the spraying machine, check whether the powder coating conveying pipeline is smooth, and the conveying volume of the powder pump should be adjusted according to the actual spraying demand, to ensure that the powder supply is uniform and stable.

Plastic spraying room

Heating stage: Start the heating system of the main oven, and raise the temperature in the oven to about 185℃ at the rate of 5 - 10℃/minute. If the temperature rises too fast, the surface of the powder coating will be cured first, and the solvent inside will be difficult to evaporate, resulting in bubbles and pinholes; if it is too slow, it will prolong the production cycle. When heating up, the temperature control system monitors and adjusts the heating power according to the temperature change in real time to ensure that the temperature rises smoothly.

Holding phase: After the temperature inside the furnace reaches about 185℃, it enters the holding phase for about 15 minutes. During the period to maintain a stable temperature, fluctuations control within ± 5 ℃, hot air circulation system continues to operate, so that the hot air circulation, to ensure that the door body is heated evenly. Insulation is used to allow the powder coating to fully melt, level and crosslink to form a hard coating film. Different powder coatings require different curing temperatures and times due to differences in chemical compositions and properties, and should be operated according to the parameters of the coating supplier. Special function coatings, such as super weather resistant and high abrasion resistant coatings, may require higher temperatures or longer holding times.

Curing oven

Out of the oven cooling: take out the cured door body and cool it down to return to normal temperature.

Natural Cooling: Place the door body out of the oven in a well-ventilated area without direct sunlight and in a clean environment, relying on the convection effect of the surrounding air, so that the heat on the surface of the door body is gradually emitted into the air, thus realizing the temperature reduction.

Forced cold air: The forced airflow produced by the fan is utilized to accelerate the air flow on the surface of the door body and take away the heat, thus accelerating the cooling speed of the door body.

Temperature monitoring: Use infrared thermometer and other equipment to regularly measure the temperature of the door surface and record temperature changes. When the surface temperature of the door body falls close to the ambient temperature (general temperature difference of 5 - 10 ℃ or less), can be considered that the cooling is basically complete.

Appearance check: In the cooling process and after the completion of cooling, the appearance of the coating film on the door body should be checked. The coating film should be free of deformation, cracking, wrinkles and other phenomena, the surface should remain flat, smooth and uniform color.

Workpiece off the line

Selection and Preparation of Industrial Robots and Hangers and Conveyor Lines

Industrial Robot: It is the key equipment of modern automated production. Industrial robots can accurately perform handling tasks through preset programs or real-time control, greatly improving production efficiency and precision, reducing labor costs and human error.

Hooks: generally made of stainless steel or carbon steel, should have sufficient strength and rigidity, can withstand the weight of the door and not deformed. Before use, carefully check the hooks, support parts have no wear and tear, fracture, there are problems in a timely manner to repair or replace. In order to ensure good contact between the door body and the hooks, and to prevent problems with the coating, the surface of the hooks should be clean and dry, no oil and rust, and if necessary, degreasing and descaling pre-treatment.

Conveyor line: Conveyor line is common chain, roller conveyor type and other types. When the door body is sprayed with plastic, it should be reasonably selected according to the size, weight and production scale of the door body. Before start-up, comprehensively check the chain, sprocket, motor and other mechanical transmission parts, add or replace the lubricant to ensure smooth transmission without abnormal sound. Calibrate the running speed of the conveyor line to ensure smooth and even movement of the door body. At the same time, check the electrical control system to ensure that the control buttons, sensors and other normal work, no short circuit, circuit breakers.

Robot Handling

Pre-treatment assembly line: the assembly line is mainly composed of conveying system, spraying system, and circulating filtration system. The principle is to use mechanical flushing to accelerate the chemical reaction, in the process of moving the door body with the conveying system, the spraying system will spray the treatment liquid evenly on the surface of the door body, react with the oil, rust, etc. and flush to remove. The circulating filtration system ensures that the treatment liquid is continuously clean and can be recycled.

Efficient production: automated continuous operation, the door body passes through each treatment process sequentially on the assembly line, which greatly shortens the treatment time, improves the production efficiency and meets the demand of mass production.

Stable quality: Precise control of treatment liquid concentration, temperature, spray pressure and other parameters, to avoid the difference of manual operation, to ensure that the surface treatment effect of each door body is consistent, and improve the stability of product quality.

Pre-treatment

Removing moisture from the surface of the door body: After washing and draining the door body after pre-treatment, moisture may still remain. When preheating, the temperature rises so that the moisture evaporates. If moisture remains, spraying will prevent the powder coating from adhering, causing bubbles, pinholes and other problems in the coating, affecting the quality and adhesion of the coating.

Improve the adhesion of powder coating: The suitable preheating temperature changes the metal lattice structure on the surface of the door body and enhances its surface activity, which prompts the resin and other components in the powder coating to form chemical bonds with the surface of the door body better after spraying and greatly improves the adhesion between the powder coating and the door body to ensure that the coating is not easy to come off in the long term.

Promote the leveling of powder coating: After the door body is preheated to a suitable temperature, the powder coating sprayed can flow and spread more smoothly under the action of gravity and heat, filling the slight bumps on the surface of the door body, making the coating more smooth and even, and improving the appearance of the door body's decorative and protective properties.

Pre-heating oven

Electrostatic adsorption principle: Electrostatic spraying machine utilizes high voltage electrostatic generator to form a strong electrostatic field at the head of the spray gun. When the powder coating is sprayed from the spray gun, it will rub with the electrode inside the spray gun, making the powder particles take negative charge. And the grounded door body serves as the positive pole, under the action of electrostatic field, the negatively charged powder coating will move quickly to the surface of the door body, thus realizing uniform adsorption.

Equipment inspection and commissioning: Before formal spraying, the electrostatic spraying machine needs to be fully inspected and commissioned. Check whether the gun head is clogged, if so, need to be cleaned in time to ensure that the powder coating can be sprayed smoothly. Test whether the electrostatic generator of the spray gun is working properly. At the same time, debugging spraying machine powder supply system, check whether the powder coating pipeline is smooth, powder pump delivery should be adjusted according to the actual spraying demand, to ensure that the powder supply is uniform and stable.

Automatic spray booth

Heating stage: Start the heating system of the main drying channel, and raise the temperature in the oven to about 185℃ at the rate of 5 - 10℃/minute. If the temperature rises too fast, the surface of the powder coating is easy to be cured first, and the solvent inside is difficult to evaporate, resulting in bubbles and pinholes; if it is too slow, the production cycle will be prolonged. When heating, the temperature control system monitors and adjusts the heating power according to the temperature change to ensure the temperature rises smoothly.

Holding phase: After the temperature inside the furnace reaches about 185℃, it enters the holding phase for about 15 minutes. During this period, the temperature is kept stable and the fluctuation is controlled within ±5℃. The hot air circulation system operates continuously to circulate the hot air to ensure that the door body is heated evenly. Insulation is used to allow the powder coating to fully melt, level and crosslink to form a hard coating film. Different powder coatings require different curing temperatures and times due to differences in chemical compositions and properties, and should be operated according to the parameters of the coating supplier. Special functional coatings, such as super weather resistant and high abrasion resistant coatings, may require higher temperatures or longer holding times.

Curing oven

Selection and Preparation of Industrial Manipulators and Hanging Tools and Conveyor Lines

Industrial Robot: It is the key equipment for modern automated production. Industrial robots can accurately perform handling tasks through pre-programmed or real-time control, which greatly improves production efficiency and precision, and reduces labor costs and human error.

Material receiver: It usually adopts special material rack or material box, and the material is mostly made of high-strength alloy steel or engineering plastics. The material frame should have a reasonable structural design, sufficient load-bearing capacity and stability to withstand the weight of the workpiece and not deformed. Before use, it is necessary to carry out a comprehensive inspection of the frame structure, to see whether there are cracks, deformation and other conditions, whether the connection parts are solid.

Mechanical Handling

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