GEINSA SUPPLIES STEEL PARTS PAINTING LINE TO CAFISUR

CAFISUR has increased its production capacity with this new surface treatment and painting installation. The success of the installation is thanks to the great engineering work of GEINSA and intense communication to determine the needs and different possible solutions. The result is evident in the quality of finish of the parts and in the enhanced production capacity.

Cafisur is a production unit of the CMZ group dedicated to industrial metalworking and bodywork. Founded in 2016, its main activity is manufacturing fairing and other components whose main raw material is sheet metal. The main goal of this plant, located in Puerto de Santamaría, is to supply third parties, mainly from the machinery and aerospace manufacturing sector.

The treatment and painting line planned and installed by GEINSA consists of a four-stage treatment tunnel with corresponding osmosis water and oil separator equipment, spray system and waste management; a dry-off oven, a cyclone-powder paint application booth, a polymerisation oven and a conveyor circuit. The equipment is controlled from a general switchgear cabinet with PLC and touch screen, equipped with a remote system with data capture, monitoring and production log, which allows reliable real-time communication.

The treatment tunnel has three treatment tanks, the first for a 40-50ºC active bath and the other two for rinsing at room temperature.

The tunnel structure, the tanks and the trays in both the spray areas and interfaces are built in stainless steel. The tanks are equipped with a high outlet and a low outlet in opposing positions, with a stop valve for potential connection to an effluent treatment device.

In the final phase, the parts are sprayed with a product that produces a film that improves the quality of the finish, with a considerable increase in their endurance in a salt fog chamber test. The spraying guarantees a consistent quality over time with minimum consumption of nanotechnology products, the functioning of which is fully automated by the general PLC.

In terms of waste management, the bath in the first tank is conducted by an authorised manager since it is an active bath. The rest of the discharges, i.e. rinse 1, rinse 2, and the discharges from the osmosis and the cleaning of the osmosis filters, are conveyed to a constructed well and, from there, taken to an auxiliary stainless steel tank. This tank is equipped with a PH control system to control the bath and a product dosing system, as well as elements for neutralising the bath if necessary and reading the PH level, which in addition to analyses of these waters ensure safe dumping into the sewage network.

When the treatment process is complete, the part enters the dry-off oven and will then be ready for the application of powder paints. After painting, the parts are placed into the 16-metre-long two-way polymerisation oven. The exits of the ovens are equipped with air curtains and heat recovery hoods, to prevent heat escaping from them.

The line is fitted with a real-time communication system between the different control elements with data recording to facilitate monitoring and the production log. Remote assistance enables service to be done faster, facilitating consultations and predictive maintenance.