A modern powder coating plant  combining elements of an automatic and manual powder coating plant

Automatic-manual cabin.

- The requirements for the powder coating shop in our company were quite extensive, because we paint details of both black steel and aluminum - recalls Jacek Czogalla from MCJ. - At the same time, our production often changes, because we have long and short series, the size of the details is very varied. The paint shop was to be as advanced as possible, i.e. as automated as possible, while maintaining flexibility - the task was not easy, you could say that it does not go hand in hand, but we have real needs. The Romer company presented us with an effective solution that fully met our requirements. It is a solution that combines elements of a power & free automatic paint shop and a manual paint shop, at the same time being very cost effective.


Transport system

The products are hung and transported on a crossbeam - it allows for painting details up to 4500 mm. Massive construction of rails and trusses facilitates the suspension of elements with a total weight of 900 kg on one transport beam.
A transport trolley, as well as devices such as a stove, dryer, washes - all these elements are equipped with five tracks with a cross section of 70 × 70, which significantly increases the efficiency of the entire line, because five transport beams can be processed in each of these devices at the same time . The transport beams travel in the paint shop semi-automatically, i.e. the beams fed into the automatic booth are picked up by a friction drive, which automatically introduces the beam to be varnished and transports it until it enters the transverse trolley located on the other side of the booth.
The drive in the cabin, controlled by an inverter, is equipped with a precise encoder which, thanks to system integration, communicates with other devices and provides them with real-time speed information.

Control system

The entire application system is controlled from the Romer ProfiControl 10 ”touch panel, which ensures complete integration of existing systems according to the Industry 4.0 standard. It is also a good solution due to the fact that Romer is a producer of electronic components and software for them, therefore, service and maintenance are carried out on a completely different plane: - producer - producer, and this opens up new possibilities.
ProfiControl allows you to program the settings of all guns as standard, both the romer ProfiSpray and Proton II series, including current and pneumatic settings without having to approach them. There is no need to purchase additional intermediary elements that are only responsible for communication.
As a standard, such painting programs also consist of settings, e.g. of manipulators - including the speed of automatic approach, up-down feed, or parameters of the so-called overspray, i.e. when the gun is to start painting before the detail and when to finish.
Depending on the pattern of guns, the ProfiControl controller is equipped as standard with algorithms that are to optimize the thickness of the applied coating based on the conveyor speed, surface to be painted, orifice wear in injectors, etc.
All these systems are very helpful in maintaining the high quality of painted details, i.e. the repeatability of the applied coating. In this case, the human factor is eliminated to the necessary minimum.

Surface preparation


This process takes place in a 7-stage two-chamber car wash. First, in the first dirty chamber (depending on the material, parts made of black steel are degreased and phosphated, then rinsed with mains water with a conductivity not exceeding 1000 μS) and in the next, second clean chamber (parts are rinsed with demineralized water with low conductivity around 10 μS). In the case of aluminum in the first dirty chamber, the details are degreased and a zirconium coating is applied to them, then they are rinsed with mains water with a conductivity not exceeding 1000 μS and in the next, second clean chamber - rinsed with demineralized water with low conductivity around 10 μS. A passivation coating is then applied to the aluminum parts and then rinsed again with demineralized water. In the first dirty chamber, the treatments are heated directly with gas heat exchangers.
A chamber car wash, combined with a very efficient pump and a large number of nozzles, ensures very good washing parameters and does not overheat chemicals.
All bathtubs are equipped with stepless liquid level sensors, which is a good solution - quite expensive, but here you do not save on good solutions. Each of the bathtubs is also equipped with a separate set of flaps to return the liquid and a separate feeding pump. In turn, the chamber itself has separate pipelines for rinsing and chemicals - all this to minimize the process of mixing the liquid.
The washing chamber is equipped with automatic cascades, we can freely program here from which bathtubs, with what doses and at what time they are to be refilled. The bathtubs are then properly replenished during the cycle.
The last of the bathtubs are equipped with a three-column demineralized water production station, operating with a strongly acid cation exchanger working in the hydrogen cycle, a strongly basic anion exchanger working in the hydroxide cycle, and the last column filters the water with activated carbon.

Drying of details

After washing, the details go to the dryer, which has its own gas heating system via two heat exchangers with a large reserve of power, which ensures a quick start of the device and allows any temperature control. The dryer has two independent fan systems that distribute the air. As a standard, the dryer has the option of programming how much and in what time intervals it is to remove moisture.

Painting process

After drying, the elements roll into the powder booth. However, before they enter there, they pass through a set of measuring gates, which are designed to measure the detail in two axes - width and height.
After analyzing the dimensions of the detail, on the basis of the program parameters set, the guns move to the set distances. Here begins the painting process in the powder booth for a quick color change. It is made of dielectric PVC. Painting takes place in an electrostatic environment with the use of romer ProfiSpray powder applicators. The ProfiControl controller, adjusting the painting program to specific elements, activates only those guns that have a given detail in front of them, thus saving the powder. The set of romer ProfiSpray guns is mounted on manipulators located on both sides of the cabin, where in the programmed up and down range, evenly feeding the paint, they paint the details passing in front of them. Thanks to the use of axles, the guns maintain constant programmed distances from the painted details. The cabin is equipped with additional places for painters for manual corrections. The paint on the cabin floor is systematically blown away by pneumatic air strips on both walls. The cabin, through the dust removal block, sucks in the air with the sprayed paint towards the slot in the middle. Most of the paint sucked in is centrifuged in the cyclone, from where the romer RP-01 is pumped into the ProfiCenter CP02 powder center using a so-called low air transfer pump. The paint that gets there is sifted through the ultrasonic sieve with variable gradation and then goes to the main tank, from where it is sucked again by obtuse injection pumps. Some of the paint that is not recovered in the cyclone goes to the dedusting block, where it is filtered out by a set of polyester filters and is waste. Clean air, free from paint particles, is filtered again through the final filter and then returned to the room. Thus, the cabin saves heat in the hall and effectively prevents the formation of an explosive atmosphere. Cleaning of filters in the filtration block takes place pneumatically in an automatic cycle, temporarily or manually by pressing a button by the operator. Each of the filters is cleaned separately, and a specially designed nozzle allows you to clean the entire filter. This is a very important element, because a poorly implemented filter cleaning system prevents the cabin from working on clogged filters.

Color change

ProfiCenter CP02 also enables automatic cleaning of the injectors and the tank. By pressing the appropriate button on the touch panel, the tank is automatically emptied of paint to go through a thorough cleaning cycle. ProfiCenter CP02 automatically cleans the tank, hoses and injectors with strong blows of air. Returning paint from the cyclone during the cleaning cycle replenishes the fresh paint bag, saving money. Automatic romer ProfiGun PA-1 powder guns during automatic retreat from the booth during the cleaning cycle are automatically blown off by a set of pneumatic nozzles mounted on the side of the booth body walls. The use of ProfiCenter CP02 in combination with a paint transfer pump provides unprecedented comfort of work, facilitating color changes.
In the ProfiCenter CP02, the ratio of reclaim to fresh paint is programmable, allowing even better process control. Certainly there are products that require high-quality varnishing - then they are painted only with fresh paint - with appropriate parameters of paint recovery. If the quality is good enough, you can set the ratio of fresh paint to reclaimed 50/50 - this is possible thanks to the stepless paint level sensor in the main tank.
The ProfiCenter CP02 has a fresh powder weight that is added up to a specific job. From there, fresh paint is sucked into the main tank, where it is additionally sifted through an ultrasonic sieve, ensuring even better quality of painted details.
KA-1 plastic cabin, MA1 series manipulators, MX1-100 series commuting, ProfiCenter CP02, this cabin configuration allows you to change the color even in 15 minutes.

Short series

A two-station powder booth equipped with tanks for waste paint, located in the vicinity of the automatic booth, enables painting short series. It is a solution for painting lengths of series, for which there is no economic justification to run an automatic booth or change its color. Painting on this stand is done by hand.

Powder polymerization

After varnishing, the workpieces enter the furnace for polymerization, powered by gas via two heat exchangers. Both the furnace and the dryer are made in fully assembled elements, which enables their quick assembly.
The control of devices, including the furnace, is very extensive and has such functions as a utility consumption meter with a full history broken down into cycles or, for example, scheduled readiness during working hours, i.e. at At 7.00 a.m. the stove may already be heated up - ready to work. The controller allows the standard setting of the heating ramps within 20 programs, each of them equipped with 10 steps, which is extremely important in the case of sensitive paints, e.g. light colors. All these functions translate into effective work and, importantly, accurate information on the costs of individual production batches.
After leaving the curing furnace, the painted parts are cooled down in their resting stations. The cooled painted parts are transported and removed from the crossbeam. Then they go to the packaging process, after which they are delivered to the recipients.

The MCJ company has been operating since 1996. Initially, she was selling groceries in rented premises. At that time, it employed three employees. In 1999, she started cooperation with an Italian company producing furniture lighting. These products quickly gained a good reputation on the market, which contributed to its development. In 2002, the company moved to its own spacious and modern building with its own technical laboratory. Since 2009, investments have been made in our own machinery park, which contributed to the increase in production, enabled the implementation of new products and ensured the comprehensive offer.

The company has a permanent offer of furniture, stairs, facade, garden, bathroom lighting, lighting fixtures, garden electric bollards, mirrors with lighting, bathroom equipment (toilet lockers, cabinets, recessed and wall shelves). It also carries out individual orders and provides services in the field of glass cutting and processing, laser cutting of various materials, laser welding (Fanuc robot), sheet metal forming, machining of aluminum profiles, powder coating.

As a result of a significant increase in sales and expansion of the commercial offer, it became necessary to expand the company. New halls with a total area of over 5,600 sq m were built, and another one, with an area of 950 sq m, is under construction. In order to promote new products, the website was expanded, new thematic catalogs were created, the company exhibits at international trade fairs (Bologna - Cersaie, Warsaw - Warsaw Home and Warsaw Build, Katowice - 4 Design Days), where innovative flush-mounted products were presented. tight bathroom lockers.

The company employs approx. 140 people. The main competences of employees include experience in operating CNC machines, knowledge of CAD programs, directional education, introducing optimization of production processes, technical improvements, construction of technological equipment, many years of experience in the development of the sales network on the domestic and foreign market, long-term business relations.


powder coating plant