With this white Vi 770 material, seal manufacturer C. Otto Gehrckens adds another high performance FKM to expand its Hygienic-Seal range for the food and pharmaceutical industry. The latest product innovation comes directly from the development lab, where the high-tech material has been specially designed by COG experts for high material stress in production systems within the pharmaceutical and food processing industry. The central concern was good capability for SIP, CIP and WFI processes, where Vi 770 has been shown to meet the strict Hygienic Design standards. Alongside outstanding resistance to the high stresses caused by the various cleaning processes, the new FKM innovation gets the job done with its very good resistance to mediums and water vapour. In addition, Vi 770 meets the increasing demand in the industry for certified ADI-free seal materials (Animal Derived Ingredients free). Like all COG Hygienic-Seal compounds, the new Vi 770 also has the key industry-related FDA 21 approval, CFR 177.2600, USP Class VI, Regulation (EC) No. 1935/2004 and approval according to 3-A Sanitary Standard 18-03. This means that the material can be used in a wide range of applications in the food and pharmaceutical industry and in medical technology, and meets even the toughest demands of these industries. The new seal material is available right now from C. Otto Gehrckens.
A high degree of microbiological safety: with the Innopas SX KHS GmbH provides a tunnel pasteurizer which with its modular design meets the growing demands of the beverage industry with its increasingly complex range of products and shorter market shelf lives. The systems supplier from Dortmund has also optimized spare part management for this flexible machine.
The beverage market is facing increasing levels of dynamic competition, with new flavors in new packaging formats hitting supermarket shelves at ever shorter intervals. Flexibility is thus becoming more of an issue when it comes to filling. The necessary pasteurization of filled and sealed beverage containers for longer shelf lives is a decisive factor here. The completely modular KHS Innopas SX tunnel pasteurizer for cans and glass and PET bottles fully satisfies these demands.
Dynamic adaptation to line behavior
The basic functions of the Innopas SX are initially identical to the tried-and-tested tunnel pasteurizer systems provided by KHS. The dynamic pasteurization unit or PU control system reacts variably to changes in conditions. If, for example, a fault occurs during the pasteurization process, the process temperatures are kept under control in the hot zones of the tunnel pasteurizer to ensure both maximum product safety and flavor stability. New features on the KHS Innopas SX include extended functions in the dynamic PU control system which result in greater flexibility and yield savings in energy and media. Much of this is attributable to the optional speed regulation function. The individual zone temperatures are automatically raised or lowered depending on the conveyor speed. “This allows the pasteurizer to dynamically adjust to match the line behavior within a range of 50 to 105% of the nominal capacity for most processes without making any drastic changes to the pasteurization units and maximum product temperature,” states Knut Soltau, product manager for Bottle Washers and Pasteurizers at KHS. This prevents stops and the corresponding consumption of media and at the same time has a positive impact on the behavior of the entire line.
With dynamic PU control from KHS the process temperatures are regulated within the hot zones of the tunnel pasteurizer to enable maximum product safety and flavor stability. With a new program for PU control the customer can independently adapt the pasteurization unit setpoint for a specific container type. Here, the full functionality of the PU control unit is maintained. “In this way subsequent product changes or new products can be easily made or introduced at any time,” says Soltau. “Bottlers can thus react quickly to changes on the market and product trends.”
KHS has also made several improvements regarding the design of its Innopas SX, with maximum emphasis placed on easy operation. The tunnel pasteurizer is clearly structured and offers optimum access which chiefly simplifies the maintenance and cleaning of the system. For this reason parts of the process engineering, such as the heat exchangers and media supply, have been relocated on the machine as modules in order to further improve servicing and machine safety.
Spare part management for the KHS Innopas SX has also been optimized. The number of components the customer is required to keep in stock has been reduced while the delivery times for spare and wear parts have been shortened. As functions can also be simply retrofitted as an option, this boosts flexibility for the customer and ensures the future viability of filling lines at a low operating cost.
Visitors will find the mycon GmbH from 18th to 21st of September in Hall 7.2c, Booth 205. The inventor Thomas Alva Edison once said: “If there is a way to do something better: Find it!”. This is precisely what mycon GmbH has done and is presenting the new dimension of industrial cleaning at the InnoTrans 2018: solutions for cleaning, stripping and coating for the railway technology sector.
mycon GmbH is a sister company of the service company Kipp Umwelttechnik GmbH, active in the development, production and sale of new products and automation technologies. Many years of experience in the field of industrial cleaning and service led to several system developments and patents with some international validity.
The systems works fast, gently, with little waste and no production stoppage – this is how the use of the mycon products pays off in short period.
The rental service of mycon GmbH also offers the possibility to use the advantages of the mycon devices without high investment costs.
Also represented at the stand of mycon GmbH will be the two investment companies Puraclean GmbH (Switzerland) and the new investment company in France, which is being established, as well as Hubei Infinity Railway Technology Co., Ltd as a co-operation partner in China.
mycon GmbH will be presenting a large number of cleaning processes for railway technology at InnoTrans.
Cleaning of heat exchangers with JetMaster ensures the functionality of air conditioning / ventilation systems
JetMaster is the gentle cleaning system from mycon for intensive cleaning of sensitive fin surfaces of heat exchangers. JetMaster is also available in automated versions.
Depending on placement and environment heat exchangers, chillers and coolers can become contaminated very quickly. Industrial dust, calcification, pollen and other influences cause continuous deposits with negative effects on function and efficiency and, last but not least, on energy consumption.
The contamination of an air-cooled condenser or chiller forms an insulating layer, reducing energy efficiency and thereby increasing the cost of power, maintenance and service. In addition, the corrosion of the fins leads to a reduced operating time of devices.
Definitely for a sophisticated and material-friendly solution: JetMaster – the gentle but extremely intensive cleaning of heat exchangers by low pressure. JetMaster is the patented process of mycon GmbH for the intensive cleaning of sensitive lamella surfaces. JetMaster works gently and extremely powerful. High-performance nozzles brings compressed air and small quantities of water specially pretreated in the device at low pressure with supersonic speed. The gentle beam penetrates deeply into the devices without bending or damaging the fine fins. The contaminants are gently but effectively released from the surfaces by cavitation effect using discharged through the jet stream. Damage to the lamellar surfaces, as possible with the use of high pressure water cleaning, is completely eliminated if the JetMaster is used correctly.
Even sensitive surfaces such as soft coatings, graphite, glass, foils etc. can be thoroughly cleaned without damage.
JetMaster process gets support: SpeedMaster
The JetMaster system from mycon GmbH has been successfully used for years to clean lamellar heat exchangers and other sensitive surfaces, even in railway companies. Kipp Umwelttechnik GmbH, sister company of mycon, has now developed another process for the cleaning of even viscous grease layers: SpeedMaster. The SpeedMaster process works just as gently as the JetMaster system. SpeedMaster can be used to clean bogies in railway areas, to clean the inside of tanks, but also to clean pipes, bars and profiles. The cleaning agent can usually be completely reusable after treatment. The release of the new process for all applications is scheduled for September 2018. A prototype system for the automated cleaning of bogies and wheelsets in the railway sector is in the works and can already be offered for the trade fair.
PowerMaster – gentle, powerful and low-waste cleaning
PowerMaster is a blast system that works with compressed air, small amounts of water and water-soluble abrasives without damaging surfaces. mycon also offers PowerMaster as a complete automated cleaning system.
The proven cleaning method is based on an environmentally friendly and water-soluble granulate, which is introduced into a compressed air jet stream. Shortly before exiting the jet nozzle, the granules are wetted with water to increase the kinetic energy. The granules do not affect the function of a downstream separator.
PowerMaster cleans, peels and removes powerful and low-waste. The system works cost-effectively in the low pressure range between 3 and 8 bar compressed air with a low water consumption. Use of the abrasives recommended by mycon, even polished stainless steel surfaces or light metal surfaces can be cleaned or removal without visual impairment of the metal surfaces. Foils, paints, varnishes or resins, greases, bituminous layers or lubricants agents can be removed gently, quickly and economically with PowerMaster. Also for cleaning plastic surfaces PowerMaster can be used with a lower air pressure value. PowerMaster can be equipped for cleaning large areas with special nozzles up to 160mm wide.
When removing minor soiling, PowerMaster can also be used with a combination device in the area of painted Surfaces.
IceMaster – Modern industrial cleaning with dry ice
IceMaster – Effective, cost-effective, infinitely automatable
Dry ice or dry snow produced from liquid CO2 directly fed in the blasting gun with a stream of compressed air and blasted onto the surfaces to be cleaned at high speed. The process allows cost-effective and unlimited automated cleaning.
The IceMaster process is patent protected
Dry ice blasting has been used successfully for a long time in numerous industrial sectors for cleaning purposes. However, high operating costs, complex infrastructure and a lack of automation capability meant that the process did not get beyond a market niche despite its good performance.
IceMaster revolutionizes dry ice blasting for industrial cleaning. Low operating costs, full automation capability, constant availability without re-ordering of dry ice pellets are only a few of many advantages. mycon also offers IceMaster in automated versions according to customer requirements.
If required, mycon can also supply complete workplaces and complete automation systems with sound-insulated solutions for the manual use of IceMaster.
One mycon special solution is the cleaning of electronic components with IceMaster without electrostatic charging.
- Minimized operating costs
- Low compressed air requirement: from 1.00 cbm air volume – min. / 1 bar
- No investment required, IceMaster is also available on a rental basis
- Constant availability
- Easy to use
- Full automation capability
Here are some application examples from various industrial and task areas:
- New: cleaning of electronic components, e.g. of controllers without electrostatic charge
- Cleaning surfaces made of plastic or metal
Cleaning of railway bogies for the purpose of weld inspection
Coating through thin-film surfaces
The cleaning of special plant parts can be significantly simplified and accelerated by the previous application of a hydrophobic protective layer. Even flexible parts such as insulators can be coated. Advantage: Experiments have shown that in subsequent cleanings with the JetMaster system, the coating is not damaged.
FilterMaster reliably cleans even large diesel particulate filters and catalysts without separating the housing
Successful cleaning of particle filters from locomotives, ships, buses, trucks and more are possible with the FilterMaster cleaning systems of the company mycon and have been executed many times.
The patented filter cleaning systems FilterMaster for trucks and more and FilterMaster for cars and more represent a new form compared to the previous concepts in the cleaning range for DPF. For the cleaning of particle filters and catalysts, the mycon systems represent a quantum leap over conventional methods.
FilterMaster for trucks and more
For filters that are openly accessible at the front, certain carbon dioxide-compressed air mixtures as well as some other industrial gases are used. Specially designed jet nozzles are used to clean the metal and ceramic filter surfaces.
Each type of filter can be precisely controlled and processed with exact repetitive accuracy. The system works in a closed circuit. Adaptive flange rings enable the almost every type of filter. Even angular filters of older design can be cleaned easily. Depending on the type of filter, the entire filter surface is automatically controlled and almost completely cleaned from the original soot and ash content.
FilterMaster for cars and more
The patented FilterMaster for cars and more cleaning system is used to clean exhaust particulate filters whose filter surfaces are not completely accessible through housings. For cleaning with this system, no separation of the filter housing is necessary. Even difficult-to-access filters of any size, even with upstream baffles or similar flow deflections can be easily cleaned with this cleaning system. Thus, a weakening of the housing by welds or corrosion resulting from welding can be excluded from the beginning.
On request, a fully automated mycon filter cleaning system is available to the customer for the particle filter cleaning with regular filter cleaning. Like all mycon machines, these cleaning stations are available on a rental basis without any investment costs including installation / commissioning on site.
About Kipp Umwelttechnik GmbH, www.kipp-umwelttechnik.de
In the field of industrial cleaning, Kipp Umwelttechnik GmbH is the specialist for thorough and gentle cleaning in industry and for building cleaning.
Kipp Umwelttechnik GmbH was founded in 1991 as a sister company to the construction company Jens W. Kipp Tiefbau GmbH, which has existed since 1971. Both companies are businesses managed by entrepreneurs.
mycon GmbH has added to the group made up of Kipp Umwelttechnik GmbH and Jens W. Kipp Tiefbau GmbH since 2002.
A new version of the popular counter display with the B+W Lens Cleaner and Photo-Clear cloth is now available. Each display holds nine B+W Lens Cleaner fluid bottles and Photo-Clear microfiber cleaning cloths. The counter display can be quickly and easily assembled in a few simple steps at the POS. Both articles are tried-and-tested cleaning products that are ideally suited to cleaning filters and lenses. They can also be used to clean glasses, binoculars, VR glasses, LCD displays, and other coated optical surfaces. The products are easy to handle and understand.
For more information on cleaning, see www.schneiderkreuznach.com
The fully equipped lens cleaner counter display can be order under ID 1092792
In demand in many places – turned into a reality by Wunderlich: Transparency has become a major trend! For all air-cooled, four-valve BMW flat twins, including all the R nineT models, the accessories specialist Wunderlich now offers transparent valve covers in its range.
The fascinating valve covers, made of latest-generation, 5-millimetre-thick technopolymer, simply replace the standard covers – and that’s all that’s needed for an unobstructed view of the valves and timing chain and how they operate and work; the engine sound does not change. The permanently stable and high-quality material has an extremely scratch-resistant surface coating and can be used in temperatures ranging from -50 to 180°C. The seal makes it resistant to all plastic-compatible cleaning products and chemicals.
No ABE or TÜV approval is required for the exclusive valve covers; they come as a set including new seals for €749.00.
35610-201 XRay valve cover set, transparent suitable for:
• R 1200 GS (2010 – 2012)
• R 1200 GS Adventure (2010 – 2013)
• R 1200 R (2011 – 2014)
• R 1200 RT (2010 – 2013)
• and R nineT
(air-cooled, four-valve flat twins engines only)
Cosmetics and personal care products must be both effective as well as dermatologically and environmentally harmless. For this reason, LAB | Laboratorio Analítico Bioclínico has extended its analytical services to this sector, which is currently en vogue.
Mª Elena Hernández (Technical Director and Manager of LAB) and Rosario Santiago (Head of the Chromatography Department), give an account of the strong commitment of the laboratory to the cosmetics sector, the methods developed to date and its expansion plans.
Q. Most of LAB’s analytical services are focused on the food, agriculture and environmental sector, a sector with high demand in Almeria and in Andalusia in general. Why the cosmetics sector?
A. Mª Elena Hernández: Headquartered in Almería, with a branch office in Huelva (a strategic location to cover the demand in the red fruit sector), our sales network covers the entire national territory. In addition, as we are part of the Tentamus Group, we also work internationally, collaborating with other laboratories of the Group.
In fact, the development of the new method in the cosmetics sector was inspired by the request of an international customer. We were very excited to meet this demand, to implement the new method in the laboratory and to offer it to our customers eventually (national and international).
Q. What are the main methods of analysis that have been carried out since then in this sector? What technology does the laboratory use to ensure the reliability of the results?
A. Rosario Santiago: Methylchlorothiazolinone (MCI) and methylisothiazolinone (MI) are heterocyclic compounds used as preservatives in cosmetics and industrial products with biocidal activity.
The laboratory has established a new chromatographic method using cutting-edge UPLC-MS/MS (liquid chromatography coupled to triple quadrupole mass spectrometry) to detect and quantify these substances.
This sophisticated equipment has allowed us to develop a chromatographic method with a limit of quantification* of 0.5 mg/kg and a limit of detection** of 0.05 mg/kg. Undoubtedly, a very sensitive method! What’s more, sample handling is reduced to a minimum.
Q. What are the main risks of the use of these ‚preservatives‘ for consumer health?
A. Rosario Santiago: The abuse of these substances in cosmetic products (gels, shampoos, creams…) can cause skin sensitization and cause allergic dermatological diseases, such as contact eczema.
Their presence in cosmetics is studied and regulated because they are considered to cause allergic reactions in about two to four percent of patients undergoing epicutaneous tests. These preservatives can be found in wet wipes (make-up remover wipes, baby wipes, intimate hygiene wipes, toiletries, etc.), hand soaps, shampoos, moisturizers, hand creams, cleaning products (dishwashers, glass ceramic cleaners), paints, varnishes and many more. Even if there is no allergic reaction, it may develop over time by continuous use of these products.
The European Commission banned the use of these compounds in non-rinse products such as body creams in 2015. At LAB we focus on EU Regulation (EC) No 1223/2009, which guarantees consumer safety in the use of this type of product.
Q. Obviously LAB is very open to the development of new methods linked to the cosmetics sector? How about other areas?
A. Rosario Santiago: LAB has always been working very closely with clients in the development of R&D projects. We are passionate about challenges and our capacity to develop multiple chromatographic methods to meet our clients’ demand is definitely not limited to the cosmetic sector but extendible to other areas of interest.
We are very proud to have developed and implemented this new method which will lead to the expansion of the laboratory into a new market area.
Q. LAB is a laboratory that has grown both in terms of human resources and scope of analytical services since its creation in 2003. How does your vision for LAB’s future look like?
A. Mª Elena Hernández: We will further consolidate LAB as reference laboratory in organic contaminant analysis and analysis of environmental and agro-food samples both at national as well as international level.
Furthermore, LAB’s objective is striving to open new lines of business by developing new methods in the sectors in which we currently work and additionally in further sectors, tailored to the demand of our clients.
*Limit of quantification: minimum quantity of a component present in the sample that can be quantified under the experimental conditions described for that method, with adequate accuracy and precision.
**Detection limit: refers to the minimum amount/concentration of a substance that can be reliably detected by a given analytical method.
Since the REACH regulation came into force, all substances manufactured or used in quantities of more than one tonne per year must be registered with the European Chemicals Agency (ECHA) in Helsinki. In principle, the rules apply to all chemical substances. The only exceptions are substances which are subject to separate legal provisions, such as radioactive substances and foodstuffs. That is why Süd-West-Chemie GmbH (SWC) has developed two new product lines in the wake of the regulation.
The REACH regulation provides for more stringent restrictions and risk assessments
The REACH regulation has three ambitious goals. On the one hand, it is intended to protect human health and the environment from risks posed by chemicals. On the other hand, the European Union wants to increase the competitiveness of the chemical industry in the EU, as well as promote alternative methods to investigate the damaging effects of substances and thereby avoid animal testing.
This applies to all chemical substances such as cleaning products, dyes and electrical appliances, and not just those used in industrial processes. Manufacturers now have to investigate the hazards posed by the substance and assess the associated risks. Furthermore, they have an obligation to replace substances which carry a high risk, or to minimise those risks as far as possible.
As a specialist manufacturer of thermosetting synthetic resins and adhesives in the industrial sector, SWC is directly affected by the REACH regulation—especially in terms of its use of the two substances formaldehyde and nonylphenol.
SWC develops low-risk alternatives
In the context of the REACH regulation, both formaldehyde and nonylphenol are classified as high-risk substances. As one of the most important organic precursors, formaldehyde is emitted, among other ways, by incomplete combustion processes. These occur, for example, in internal combustion engines in motorised vehicles, in foundries, or in the manufacture of plastic products. Furthermore, formaldehyde is used as a starting material for many chemical compounds. Therefore, its classification as a carcinogen and probable mutagen will have far-reaching implications for businesses.
The new classification means that businesses will have to make large investments in safety equipment, such as extraction systems, in order to be able to ensure adequate protection of health and the environment. This represents an enormous financial burden, particularly for small and medium-sized companies, which make up the majority of SWC’s customers.
That is why the manufacturer based in Neu-Ulm in Swabia has developed an effective solution. This means that the quantities of free formaldehyde in almost all resin systems can be decreased to below the 0.1 % threshold. Formaldehyde is thus no longer hazardous and no longer needs to be included in the classification or the safety data sheet. In the SWC product series, this new system is denoted “RF”, for “reduced formaldehyde”.
The substance nonylphenol is also used in the industrial sector, mainly as a precursor in the manufacture of polymers and adhesives. It is classified as high-risk due to its hormonal effects on fish. Now SWC can replace up to 100 % of this substance with a substitute material produced from renewable raw materials, so that we will no longer be dependent on crude oil in the future. The flagship here is Stabiliser 83208, which is mainly used in the abrasives industry.
Customers and the environment benefit
With its two new product lines, Süd-West-Chemie GmbH does not just comply with the requirements of REACH to reduce the emission and spread of dangerous chemical substances; it simultaneously offers its customers more cost-effective and low-risk alternatives.
Further information is available at: www.sued-west-chemie.de
Automation, networking, decentralization, and real-time capability are no longer unfamiliar concepts. In both intralogistics and external logistics, the trend towards flexible systems is well underway, and its inexorable expansion will make goods handling even more efficient, safe, and economical. This evolution requires interfaces and connections for data, energy, and signals that ensure safe operation of the systems. Stäubli Electrical Connectors, the specialist for reliable, high-performance connectors, offers efficient standardized or tailored solutions for indoor and outdoor use. Its products are distinguished by their very high standard of safety and provable quality.
In logistics, everything is constantly in motion. Goods move from the warehouse to shipping, are stocked when they arrive at the loading dock, and are relocated by transport vehicles. Electrically driven Automated Guided Vehicles (AGV) are an integral component of forward-looking logistics applications. Powered by batteries, they navigate through warehouses or container ports and make a significant contribution to increasing efficiency and reducing costs in logistics processes. Furthermore, these vehicles allow for emission-free, environmentally friendly transport.
Automatic battery replacement systems and high-performance charging stations are used to keep the AGVs in constant motion and prevent workflow disruptions. An important factor to help avoid downtimes and keep costs down is rapid charging. The Swiss company Stäubli Electrical Connectors has perfectly tailored, powerful, safe solutions for nearly every challenge in charging applications.
Simple, flexible connector solution
Automatic battery replacement is a robot-controlled process, so the power transmission connections must be pluggable and separable. Alignment errors up to a certain degree require compensation, and the connection solution must withstand a high number of mating cycles. The CombiTac modular connector system from Stäubli allows free configuration of the transferred media. For this application it is equipped with an additional frame to compensate for guidance inaccuracies. A selection of various contacts and high-density contact bases is available; special last-mate-first-break contacts monitor and check the connection status, providing greater safety. A 10-Gbit module for industrial Ethernet applications meets the requirements of CAT6A and is suitable for real-time data exchange.
To tailor the connector solution to the individual application, Stäubli Electrical Connectors can draw on over 50 years of experience to develop customer-specific designs. Sales engineers and designers provide support throughout the entire process, which includes supplying 3D CAD models for easy integration into customer drawings, as well as one-to-one samples. The Stäubli Multilam contact technology is designed for very high numbers of mating cycles: Products from the automation technology range (Dockingline) guarantee both up to a million mating cycles and reduced-maintenance operation of the system. Our broad industrial expertise allows us to design ideally tailored standard or special customer solutions.
Automatic quick charging system
For automated logistics processes that run smoothly without operator intervention, power must also be supplied autonomously. In the process, the automatic charging system communicates not only with the vehicle, but also with the higher-level software that controls and monitors the entire charging process.
There is a clear trend towards flexible systems that run without rails, tracks or guide markings , or whose guide markings can at least be modified without significant construction expense. Therefore, flexible charging systems that can be adapted to both the application and the existing infrastructure are in demand.
With the QCC (Quick Charging Connection) system, Stäubli Electrical Connectors offers a market-ready automatic connection solution that is already proving its worth in the field. Its core is the unique Multilam technology, in which the constant spring pressure of the Multilam louvers ensures that the connection between the contact surfaces remains consistent through the entire lifespan, allowing constant high efficiency power transfer. Furthermore, the Multilam technology offers a self-cleaning effect with every mating. This allows high currents to be transferred continuously without additional cleaning or maintenance. These properties allow the shortest charging time for AGV batteries so as not to disrupt the work and schedule of the AGVs.
The charging rhythm can be adapted to the application. Regular, short charging cycles make it possible to keep the batteries that are used small, which has a positive effect on vehicle weight, on-board space requirements, and operating costs. Recharging occurs in scheduled pit stops or during reloading operations at charging stations along the route. Such brief interim charging, so-called “opportunity charging”, can be easier on the batteries than full charging. This quick charging system from Stäubli is designed for over 100,000 mating cycles for many years of continuous operation.
The charging devices also have a patented mechanical guide with high tolerance compensation that can correct for positional inaccuracies and misalignments. An optional automatic self-cleaning system with compressed air removes possible foreign matter in the charging device in order to ensure reliable, low-maintenance operation – both indoors and outdoors. Thanks to its watertight design (IP55), this innovative system also prevents significant contamination and water penetration, which could lead to dangerous short circuits.
Safety is also ensured: The Stäubli system is designed in such a way that all live parts are protected against contact in every situation, whether connected or disconnected. The power and signal contacts are not exposed until the connection is fully mated, and the electronic release occurs at the start of the charging process. This complete contact protection up to the end of the connection process and the additional electronic release makes the system doubly safe. There are no exposed live parts such as overhead lines or power rails that could be touched.
The safe, versatile, adaptable, powerful charging solutions from Stäubli will provide effective support for increasing the efficiency of logistics processes in the future.
New process of Kipp Umwelttechnik with the support of the University of Paderborn and the sister company mycon in development
Kipp Umwelttechnik and the University of Paderborn are developing the SpeedMaster: a new process for cleaning and coating pipes (inner and outer surfaces), rods, strips, profiles and wires. This development takes place as part of a project funded by the Federal Ministry of Economics and Technology within the framework of the Central Innovation Program also known as ZIM. SpeedMaster delivers high cleaning and coating speed with high quality. The coating requires only an extremely small volume of compressed air.
The sister company mycon already produced CO2 cleaning systems for the cleaning of inner and outer pipe surfaces and brought considerable support from these previous experiences.
Advantages of the SpeedMaster in the area of cleaning stainless steel pipes
The production of seamless stainless steel tubes results in residues of highly viscous pulling lubricants. These pulling lubricants must be removed before the subsequent annealing of the tubes. Otherwise, during the annealing process, carbon compounds migrate from the pulling lubricants residues into the structure of the stainless steel tube and lead to carburizing, which then results in a considerable quality defect, i.e. rust.
The removal of the pulling lubricants is difficult with existing methods, in particular with small internal dimension pipes. In existing practices, these tubes are placed in a bundle for cleaning into a liquid container with kerosene prior to annealing process. However, this method is not always successful, especially for tubes with small diameters in the inner tube area.
Low viscosity pullers from the outer and inner tube surfaces can also be cleaned using mycon CO2 snow jet method (IceMaster). However, this method, developed by the sister company my-con, limits the viscosity of the pulling lubricants.
New method of Kipp Umwelttechnik with the support of the University of Paderborn and the sister company mycon
Kipp Umwelttechnik, together with the University of Paderborn, is developing a new cleaning process in which outer and inner pipe cleaning is integrated directly into the production line at the production speed of the production line. This enables the pipes to be directly fed to the annealing process or other working steps after leaving the production line with-out any time delay. The cost for additional cleaning baths, crane, as well as the personnel expenses can be saved. The cleaning quality will be increased significantly. The cleaning of the inner pipe surfaces can also be carried out for extremely small-dimensioned pipes from an inner diameter of 1 mm over long lengths.
SpeedMaster can also be equipped with a coating head. The coating of outer tube surfaces, profiles, rods, and strips can also be carried out at production speed.
The development of Kipp Umwelttechnik can be used within the production line. An application of the system now also makes it possible to clean and coat previously produced pipes before further processing.
Prototype pipe cleaning system
Picture: Prototype pipe cleaning system
VIEMETALL Viersener Metallverarbeitung Pottel GmbH & Co. KG comes to Kipp Umwelttechnik with a concrete problem in pipe cleaning
VIEMETALL Viersener Metallverarbeitung Pottel GmbH & Co. KG (VIEMETALL) came to Kipp Umwelttechnik with a special problem. VIEMETALL had the order of a customer galvanizing pipes for plug-in systems. Despite a long residence time in an upstream acid bath, after galvanic coating, the quality of the coating was not optimal. Dark shadows visibly appeared on the surface because the previous cleaning was insufficient.
VIEMETALL has been represented in the electroplating market since 1953 with a comprehensive galvanic surface finishing program.
In addition to the galvanizing of small parts and up to 6.5m long pipes, flat and semi-finished products, the emphasis is on chrome plating, electro-polishing of stainless steel, tinning of conductor rails made of aluminum and copper as well as the hot tinning of copper strip and wire material. VIEMETALL has many years of experience in all these areas, but so far has not been able to solve the cleaning problem satisfactorily in this particular case.
Kipp Umwelttechnik uses the prototype of the new SpeedMaster process for cleaning and coating pipes for the first time with a customer – SpeedMaster achieves a better cleaning effect than acid bath
Kipp Umwelttechnik used the new SpeedMaster process technology to clean some of the pipes made available by VIEMETALL for testing purposes from the outside. The galvanic zinc coating of the tubes after the cleaning resulted in a perfect quality of the coating with an attractive appearance.
Kipp Umwelttechnik will gather more experience directly from VIEMETALL. For this purpose, the company VIEMETALL Kipp Umwelttechnik first receives a system for outer tube cleaning. However, VIEMETALL also sees opportunities for the future to use the inner tube cleaning and coating system of Kipp Umwelttechnik.
Release of the new procedure planned for all applications by September 2018
For cleaning, Kipp Umwelttechnik can already offer test facilities for test runs. From September 2018, the release of the systems is also planned for the coating. For the area of the inner pipe surfaces, it is also intended to include systems, e.g. for ceramic coatings will be offered.
PaintExpo 2018 is stepping up to the starting line with record-breaking participation once again. More than 520 exhibitors will be on hand when the 7th edition of the world’s leading trade fair for industrial coating technology opens its doors on the 17th of April. Companies from 29 countries, including all of the sector’s market and technology leaders, will present innovations and further developments for the optimisation of liquid painting, powder coating and coil coating processes on 165,000 square feet of net exhibition floor space.
PaintExpo will transform the Karlsruhe Exhibition Centre into a hub for industrial coating technology from the 17th through the 20th of April, 2018. With more than 520 exhibitors and roughly 165,000 square feet (15.500 square meters) of net exhibition floor space – a 15% increase as compared with 2016 – the 7th edition of world’s leading trade fair for industrial coating technology will be the largest to date and will be held for the first time in three halls at the Karlsruhe Exhibition Centre (Germany). The exhibiting companies come from 29 countries – roughly 36% from outside of Germany. And thus internationalism is also on the rise once again for PaintExpo.
Solutions for All Sectors, All Materials and All Applications
Globally unique offerings for coating and painting all materials, in all industry sectors and for all applications will await visitors from companies with in-house coating operations and job-shop coaters. PaintExpo’s exhibition programme covers coating equipment for liquid, powder, UV, immersion and coil processes, paints and enamels for all processes, application systems, spray guns and atomisers, automation and conveyor technology, cleaning and pre-treatment, drying and curing, environmental technology, pneumatics, compressed air supply and exhaust purification, water treatment, recycling and disposal, accessories, masking, measuring and test technology, quality assurance, identification, paint stripping, job-shop coating, services and technical literature.
Experience Innovations Live
“Whether for liquid painting, powder coating or coil coating, the exhibitors will present new and further developed products, processes and services in all segments, and will highlight current trends. These solutions are laid out to further enhance quality, energy and materials efficiency, flexibility and sustainability”, reports Jürgen Haußmann, managing director of event promoters FairFair GmbH. A further issue on which attention will be focused at this year’s PaintExpo is the digitalisation of painting processes and the integration of Industry 4.0 into painting operations. “New products are traditionally presented to the expert visitors at the trade fair – often in the form of live presentations”, adds Jürgen Haußmann. Amongst others, these include a self-programming painting cell for the efficient coating of products with a manufacturing lot quantity of 1, as well as highly flexible, easy-to-program painting robots and automation solutions which have been specially developed for industrial applications. New solutions for blasting, grinding and ionising metal, plastic and wooden surfaces will be premiered at PaintExpo, as well as products and processes for more economic and environmentally friendly cleaning and pre-treatment, along with system concepts which reduce energy consumption for powder coating and liquid painting processes, and at the same time increase flexibility with regard to coating, lot quantities and expandability. Where application is concerned, new and enhanced paint guns and atomisers, as well as alternative atomising gases, are increasing material efficiency and improving quality. Product developments with optimised functional and decorative properties are opening up new opportunities and making it possible to reduce the required number of painting steps in the case of liquid paints, UV paints and powdered enamels. Current innovations for dry scrubbing solutions, test and inspection systems, accessories such as covering materials, painting hangers, filters and pumps, as well as paint stripping and packaging solutions are no less interesting.
PaintExpo will take place at the Karlsruhe Exhibition Centre from the 17th through the 20th of April, 2018. The world’s leading trade fair for industrial coating technology will be open Tuesday through Thursday from 9 a.m. to 5 p.m., and on Friday from 9 a.m. to 4 p.m. Further information, the exhibitor and product index and the ticket shop can be accessed at www.paintexpo.com.