Application: Spray UV coatings precisely with a reliable process
What this application is about
In practice, solutions range from flexible manual workstations to indexed, robot-assisted series-production systems. The spray equipment, material supply and movement sequence must be suited to the coating material and the workpiece.
Benefits and applications of UV coatings
The application mainly concerns plastic, wood, metal, glass, paper and composite materials. 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.
Typical requirements for the spraying process
Even small fluctuations in material pressure, viscosity, distance or movement control can change the coating visibly or functionally. Typical requirements include:
- even layer for complete curing
- Protection of the material against accidental UV exposure
- Adaptation to reactive and partly highly viscous systems
- clean material paths and short dead spaces
- Avoidance of shadow zones in complex geometries
- matching application quantity, UV dose and cycle time
Spray application and UV curing as a complete process
UV-curing varnishes remain reactive until irradiation. Therefore, spray booths, material paths and cleaning must be designed in such a way that uncontrolled curing by UV or strong ambient light is avoided. After application, wet coating, ventilation and the UV dose specified by the paint manufacturer influence the result.
In complex geometries, shadow areas and accessibility through UV radiation must also be taken into account. The application can provide a uniform layer; complete curing must be ensured in the customer's UV process.
- Even wet layer
- Protection of the material from premature curing
- tuned ventilation before the UV zone
- Consideration of shadow and edge areas
- short cleaning times during production interruptions
Krautzberger solutions for spray application and material supply
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 hand or automatic spray guns with suitable material-carrying components, light-protected material containers and pipes, material pressure controllers and integrated coating systems. The technically and economically suitable combination is selected for the specific medium, components and required production output.
Components, industries and fields of application
The application is used in different industries and component groups. Typical examples are:
- Plastic housings and visible parts
- Wood and furniture surfaces
- Parquet, laminate and profiles
- Protective coatings on electronics and technical components
- High gloss or scratch-resistant topcoats
- Paper, packaging and decor applications
Manual, partially automated or fully automatic
The spray station and UV curing must be considered as a coherent process. Component transport, exposure, temperature and shadow areas influence the result as well as spraying image and layer thickness.
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.
Result for quality and economy
- Short hardening and throughput times
- high surface performance with defined layer
- reduced space between application and curing
- Reproducible production processes
- Flexible manual and automatic application
- coordinated material management for reactive media
Tests with original material and sample components
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.
In the technical test centre sprayability and layer formation are tested; the final UV curing is to be validated with paint supplier and system concept.
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
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Contact for your application
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
UV coatings combine short curing times with protection, decor or technical functions. In order for the surface to be convincing, the application and later UV process must be coordinated – especially when components and production processes differ.
