Application: Evenly coat screws and bulk small parts in rotary systems
What this application is about
The right solution starts with the entire process rather than an individual gun. Spray pattern, nozzle design, material pressure, delivery, component movement and cleaning must be considered together to keep the application stable and repeatable.
Purpose and benefits of the coating
The application mainly concerns metal, plastic, rubber-metal and other bulky small parts. The required effect occurs only when coating material, substrate, layer thickness and subsequent drying or curing fit together. The spraying process must therefore be adapted to the concrete material system and the real production conditions.
Alongside surface quality, material consumption, cleaning effort, system availability and reliable repeatability also matter. A sound technical solution therefore combines controlled atomisation with a stable material supply that is easy to regulate.
What matters with the application
Even small fluctuations in material pressure, viscosity, distance or movement control can change the coating visibly or functionally. Typical requirements include:
- even distribution in the moving part bed
- Avoiding bonding and agglomerates
- defined total application quantity per batch
- Abrasion and solid load of spraying technology
- Adjustment of spray phase, rotation, temperature and drying
- quick cleaning between batches
Tuning drum movement, spray pulse and drying
In the mass small part coating, screws, fasteners and other small parts are moved in drums or rotomates. The components must be continuously rotated during spraying in order to reach all surfaces. Too much liquid can bond parts or form agglomerates.
The amount of spray, drum speed, loading and drying are therefore adjusted together. The spray guns must be positioned robustly and protected against splashes.
- Uniform rotation of the parts
- Dosed spray pulses instead of flooding
- Avoiding bonding and aggregation
- concerted intermediate and final drying
- Cleaning in case of material changes
Spraying technology and material supply from Krautzberger
Krautzberger treats application and material supply as a connected system. Depending on the task, manual and automatic spray guns, suitable air and material nozzles, material pressure tanks, diaphragm pumps, pump and lifting stations, and material pressure regulators can be combined.
In automated processes, spray guns can be integrated into mounts, lifting devices, axes or robots. Material changeover valves and flushing equipment support applications with several colours or media. The specific selection depends on viscosity, solids content, application quantity, cycle time and component geometry.
For fine surface finishes, various XLINE nozzle combinations and spray patterns are available. With highly viscous, abrasive or sedimenting media, sufficiently large flow cross-sections, suitable material combinations, agitators and pressure-stable delivery become more important.
The focus is on automatic spray guns for rotomates or drum systems, material pressure vessels, pumps, agitators, material pressure controllers and wear-resistant nozzles. The technically and economically suitable combination is selected for the specific medium, components and required production output.
Typical applications
The application is used in different industries and component groups. Typical examples are:
- Screws and nuts
- Springs, clips and fuses
- Sliding and corrosion protection coatings
- Adhesive agents for rubber-metal parts
- Sealing and plastic small parts
- Marking and functional coatings
Process integration and automation
Spraying time and quantity of material are adjusted to batch weight, rotational movement and drying phase. The spray gun is positioned so that the active part bed is reached and the container wall is wetted as little as possible.
In addition, component feed, extraction or ventilation, cleaning, media change and accessibility for maintenance work must be taken into account during the system integration. This keeps the process stable not only in the pattern run, but also in everyday production.
Benefits for your production
- even coating of large quantities
- low effort for workpiece carriers
- reproducible application quantity per batch
- Flexible processing of different functional coatings
- economical production of series and batches
- coordinated spray and material supply
Process design at the Krautzberger technical centre
Liquid media and coating materials with similar names can differ considerably in viscosity, solids content, solvent base, wetting and drying. A reliable choice of spray gun, nozzle and material supply should therefore be made using the original material and a representative component.
With a representative batch, rotation, spray time, quantity of material, drying and separation of the parts are optimized.
On this basis, the spray pattern, material quantity, pressure, distance, movement and cleaning sequence can be defined. The result is an application solution suited to the medium, the geometry and the intended production process.
Related products
All products
Find the right application solution together
Looking for a spray gun, an automatic spray gun or a complete material supply for this process? Krautzberger helps you select and design suitable spray technology, nozzle configurations, delivery and regulation.
Contact Krautzberger to discuss your medium, component, production volume and desired result. Together, we assess how the process can be implemented safely and economically.
Industries for this application
Screws, springs and fasteners are sprayed together in moving containers so that many parts can be coated without individual fixtures. In automotive manufacturing, plastics processing and aviation, uniform application is essential despite differing geometries.
