PRE-TREATMENT AND CATAPHORESIS
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Reducing consumption is something that has always featured very highly in all of Geico’s work and it is one of its mainstays, when it comes to environmental sensitivity. More specifically, the aim is to limit and even reduce the volume of water used and the discharges of spent water; this is achieved through on-process water treatments which in turn allow an overall reduction in the volumes of waste water and the consumption of renewing water.

The envisaged solutions concern:

  • systems for the removal of oil from the degreasing and pre-treatment stages;
  • systems for the removal of sludge and solids in pre-treatment;
  • systems for the recirculation and production of demineralised water in pre-treatment and cataphoresis.

SLIDE-copia4One of Geico’s strongest features is that it carefully analyses their clients’ needs, often anticipating them and, on each and every occasion, coming up with the best possible solution – and all with a particular focus on the environment: the goal is that of gradually reducing the impact on the world that surrounds us.

Waste water is generally treated with chemical/physical processes, in accordance with international regulations.

Where particularly stringent limits apply, the plants can be enhanced with membrane treatments (ultra-filtration or the like), biological treatments (removal of organic pollution, surfactants) or other, ad hoc treatments (evaporation, mechanical, physical) depending on the specific requirements.

With these systems Geico is capable of treating all waste waters emanating from the painting department (pre-treatment, cataphoresis and painting booths).

slide136Thanks to its “zero waste” solution, Geico has totally eliminated the problem of liquid discharges; water consumption at the entry point coincides with that strictly associated both with its evaporation during the various stages of the process and the processing consumption. This will result in only solid and semi-solid waste being discharged. This solution has been put forward following an analysis of the water costs (consumption and discharge), of the energy carriers and a check of the availability of low-cost waste energy.

It is possible to offer two types of solutions: on the one hand, maximum use of evaporation processes and minimum use of chemical methods, and on the other, chemical-physical-biological processes integrated by a minimum part of evaporation processes.

Both solutions envisage the total reuse of treated water.

slide_caldofreddoThe electrophoresis paint line normally requires a cold water exchanger in order to maintain the temperature inside the bath within given levels; similarly the pre-treatment line requires sources of hot energy for heating the degreasing and phosphating baths. This requires the integration of traditional energy carriers with combined solutions that are then placed on the plant.

The combined use of cold production systems with the recovery of the condensation heat in actual fact allows consumption to be optimised significantly, which is one Geico’s main objectives.

The many advantages of J-Jump 4C (4 columns) include the possibility of processing bodies with different cycles on the same line, lower initial investment costs and the reduced times required for possible expansions in the future and the adaptability of the cycles to the bodies to be processed. Unlike other products from the J-Jump range, this system also offers the possibility of processing larger bodies such trucks or SUVs.

Jump also makes it possible to: process bodies with different cycles on the same line, reduce initial investment costs and the times required for the plant’s possible expansion in the future, a greater production capacity compared to other stop & go systems (in which the dipping time is down to the natural sinking of the body) given that the system thrusts the body into the tank during the dipping phase and reduced space requirements and lower volume tanks compared to a continuous conveyor.

The modularity and repeatability of the system on every tank ensure that the J-Jump is easy to run and maintain.

DSC0537There are many advantages to the J-Jump 2C (2 columns) all of which are important. Those particularly worthy of mention include: the possibility of processing bodies with different cycles on the same line; lower initial investment costs and reduced times for possible expansions in the future; reduced space requirements compared to a continuous conveyor and the possibility of rotating the body in the dipping and re-surfacing phase.

The J-Jump 2C is a conveyor system with a combined movement which makes it possible to dip the bodies with a vertical movement or a rotating trajectory or a mix of the two movements depending on the body’s characteristics and shape.

Every tank has a modular handling system and it is possible (using only the roller conveyors) to allow a body to pass over a tank in which the preceding body is immersed (the body’s so-called ‘jump’).

It features greater production capacity compared to other stop & go systems (in which the dipping time is down to the natural sinking of the body) given that the system thrusts the body into the tank during the dipping phase. Smaller space requirements and reduced tank volumes compared to a continuous conveyor.

slide2The J-Jump 2CL (2 Lateral Columns) has all the advantages that are a feature of J-Jump and that have transformed it into one Geico’s leading products. Because it is a conveyor system with a combined movement, it offers the possibility of processing bodies with different cycles on the same line, with lower initial INVESTMENT costs, reduced times for expanding the plant in the future, and a body capturing system that is both simple and functional.

The system has a greater production capacity compared to other stop and go systems (in which the dipping time is down to the natural sinking of the body) given that it pushes the body in the tank during the dipping phase. It also boasts reduced space requirements and lower volume tanks in comparison with a continuous system.

This system can cope with medium to light loads, guaranteeing correct handling and avoiding the risk of pieces floating.

The modularity and repeatability of the system on every tank ensure that the J-Jump 2CL system is easy to run and maintain.

SLIDE6The J-Jump 1C (single-column) has all the features that have made J-Jump one of the stars of Geico’s already successful range of products.

Of these, those most worthy of a mention are: the possibility of processing bodies with different cycles on the same line; lower initial investment costs and the reduced times for possible expansions in the future; reduced space requirements and the possibility of rotating the body in the dipping and re-surfacing phase.

This is, in actual fact, a conveyor system with a combined movement. It is possible to dip the bodies with a vertical movement, with a rotating trajectory or a mix of the two, depending on the body’s characteristics and its shape.

Every tank is fitted with a modular handling system and it is possible to let a body pass over the tank in which the preceding body is immersed (the body’s so-called ‘jump’).

This system boasts greater production capacity compared to other stop & go systems (in which the dipping time is down to the natural sinking of the body) given that the system thrusts the body into the tank during the dipping phase. It also guarantees reduced space requirements and lower volume tanks than continuous conveyors.

SLIDE7J-Max is a conveyor system that is an evolution of the classical J-Jump systems; it allows bodies to be treated for stop & go plants with a high production rates with just one processing tank. It is a conveyor system for handling and dipping bodies on the pre-treatment and cataphoresis lines and is recommended for plants where pieces can be dipped into the tank with a rotational movement or the combination of a rotational and translational motion. The system has been designed to be used in those stages with long processing times and where it has been decided not to use a double tank.

On entering the tank the body is taken above it by means of lateral roller conveyors; meanwhile, two trolleys, positioned along the two longitudinal sides of the tank can move along its entire length where there is a device that can make the bodies rotate inside the tank.

The body is transferred by the infeed roller conveyors to one of the two trolleys that, with a rotating movement, dips it into the tank.

The trolley moves the body during dipping, which, at the end of the processing time, after a rotating movement that makes it re-surface, is transferred from the trolley to the outfeed roller conveyor. By passing over the tank the trolley returns to the infeed zone whilst the trolley positioned on the other side is transporting a dipped body from the tank’s infeed to its outfeed.

In practice the two trolleys are alternately carrying a body beneath the surface of the process liquid or chemical  for the entire length of the tank, and then return to the initial part, above the tank.

Highlights:

  • Processing stages with long dipping times, consisting not of two separate tanks (compared to other conveyor systems) but a single, longer tank.
  • The body rotates as it enters the tank.
  • Greater production capacity compared to other stop and go systems on which the dipping time is down to the natural sinking of the body.
  • Smaller investment/space requirements compared to a continuous conveyor
  • Modularity and repeatability of the system on every tank assist with running and maintenance and the management of replacement parts.

SLIDE15Characterised by its extreme simplicity of operation and maintenance, the LeadDip conveyor system allows bodies to be handled continuously and in stop&go and it is particularly recommended for average production runs (less than 40 bodies per hour).

LeanDip allows the body to be moved horizontally and dipped, by rotation, into the painting plant’s processing tank.

LeanDip also allows you to adjust the speed of rotation in accordance with the body to be treated and to jump the tank.

Only a small part of the surface of the conveyor system is immersed in the tank, which ensures reduced pollution of the baths as well as making it easy to clean and maintain.

The tanks are not as long or wide as those found in traditional systems, resulting in a smaller footprint. It means that LeanDip is a green system with considerably reduced energy consumption levels.

slide17-2The LeanDip HP conveyor system is the continuous body handling system that is suitable for high rates of production; it allows the body to be moved horizontally and dipped into the painting plant’s processing tank by rotation.

LeanDip HP is an extremely simply, flexible system which makes it possible to jump the tank and adjust and modulate the speed of rotation when entering and exiting the tank.

Only a small part of the surface of the conveyor system is immersed in the tank, which ensures reduced pollution of the baths as well as making it easy to clean and maintain.

The tanks are not as long or wide as those found in traditional systems, resulting in a smaller footprint. It means that LeanDip is a green system with considerably reduced energy consumption levels.

IMAG0008This is a simple, reliable conveyor system that is particularly suited for continuous, high-production plants that allows the body to be rotated during the dipping and re-surfacing phase in the processing tank.

The Ro-Dip patent was originally made by ABB, from whom Geico acquired the license for installation in different countries around the world.

The trajectory of the body’s movement in the entry and exit phase from the tank allows its geometry and volume to be reduced when compared to more traditional systems. As a result, energy consumption is kept down.

SLIDE11The EMS is a movement system whose main characteristics are cleanliness, silence and cycle flexibility. It is mainly used in assembly areas and where quick movement is required.

In painting, it is used in low-production plants as a conveyor system and for dipping bodies for pre-treatment and cataphoresis.

The EMS is a simple, reliable system that is easy to maintain and operate. By varying the number of trolleys, you can adjust production. It also features automatic loading of bodies.

slide5The programmed cranes are a simple system used, in the main, for handling large pieces (such as, for example, bus and truck chassis) in areas with low production runs.

Maximum production with programmed crane plants is 8 to 10 pieces per hour, but it is also possible to increase this by simultaneously loading several pieces onto one skid.

slide114Simple and reliable, this is a traditional conveyor system that has been improved by Geico over the years and that is specifically intended for pre-treatment and cataphoresis plants, because it allows the body to be moved, dipped and returned to the surface in the processing tanks.

Notable for its high production capacities, the system features automatic loading and unloading operations and is easy to maintain and operate.

The conveyor’s angle of entry, for dipping the body into the tank, can be as much as 45 degrees, which reduces the sizes of the tanks considerably.

slide112The reliability and simplicity of the system and its operation: these are the horizontal pendulum’s two key strong points, making it particularly suited to very high production runs.

This is as a result of its method of operation: it is, in fact, a traditional conveyor system which allows the body to be moved, dipped and brought back to the surface in the processing tanks by means of two chains positioned in the enclosure to the side of the body. This maximises the production capacity of a painting plant, having as its only restriction to production the length of the loading area.

The conveyor’s angle of entry, for dipping the body into the tank and bringing it back to the surface, can be as much as 45 degrees, which reduces the sizes of the tanks considerably and ensures high production capacities.

SLIDE24Power & Free is an aerial conveyor system for pre-treatment and cataphoresis. Simple and reliable, it allows the movement, dipping and bringing back to the surface of the body in the processing tank by means of a chain positioned in the enclosure above the body; however, in the sealing areas, it can be used for adjusting the body’s altimetry.

The conveyor’s angle of entry for dipping the body into the tank can be as much as 45 degrees which reduces the sizes of the tanks considerably.