Batch Oven Optimization · well as document the part curing process. • When used in conjunction with the Col -Met SmartConnect App, you can remotely monitor part and oven temperature,

Todays Webinar: Batch Oven Optimization

New Series

COMPLETEDAvailable on YouTube



Batch Oven Optimization

Presented By: Bill Van Buren – Regional Sales Manager

Bryan Willis – Technical Specialist

Batch Oven OptimizationThree Main Business Segments:

1. Core / Catalog Equipment

2. Engineered Projects (EP)

3. RP Filtration Products

Core / Catalog Equipment:


Engineered Projects (EP):


- - - - Timeline - - - -

RP Filtration Products:

07.2017 Acquisition 2018 Integration 2019 / 2020 GROWTH

§ Filter Specialist§ New Products§ New Programs§ Sales Support


• Col-Met Batch Ovensü BO Style Batch Ovenü VHD Style Batch Oven

• “Catalog” vs Process Specific Ovens• Air vs Part Temperature• Oven Optimization• Oven Enhancements

Presentation Overview:


Col-Met Curing Solutions• Batch Ovens, two configurations:

– “BO” Batch Oven

– “VHD” Batch Ovens

• Batch Cure Chambers– Used to accelerate curing process

– Typically operate @ < 140° F

• Process Ovens (EP Product)– Used with automated /

conveyorized systems

– Site / process specific designs

• Electric Batch Ovens (EP Product)– Site / process specific designs


Batch Ovens Overview • Batch Ovens: used in lower volume manufacturing

to processes parts in “batches”• Multiple ovens used to increase capacity• Parts transported into oven in a variety of ways:

– Manually– Cart via floor track– Overhead rail or crane

• Used to cure liquid or powder coatings, also used to dry parts or “gel” powder

• Typical processes utilizing batch “system” / oven:– Clean / Coat / Cure– Clean / Dry / Coat / Cure– Clean / Dry / Coat / Gel / Coat / Cure


“BO” Batch Oven Components:

12

Burner

Exhaust Fan

Recirculation Fan

16 GA. Aluminized Ductwork

Burner Box

20 GA. AluminizedInsulated Panels

Internal Structure

Trim

Support Steel

Door

“H” Slot Adjustable Nozzles


“VHD” Batch Oven Components

13

Exhaust Fan Recirculation Fan

Discharge Ductwork

20 GA. AluminizedInsulated Panels

Control Panel

TrimBurner Enclosure

DoorValve train


14

“BO” Batch Oven “VHD” Batch Oven

BO / VHD Feature Comparisons

Smart Control Panel


Catalog vs Process Specific OvensCatalog Ovens:• Pre-engineered to meet a wide range of

general conditions.• Information required for quotation:

– Size: W x H x D– Fuel Source: Natural Gas or Propane– Entry / Exit Preference: Single (SE) or Dual (D)– Door Type: – Roof Height: Exhaust Stack Length


• 8’W x 8’H x 14’D

Curing Solutions and ConsiderationsOven Size Required (interior):

“BO” Batch Oven

“BO” Batch Oven

“VHD” Batch Oven

“VHD” Batch Oven

Catalog vs Process Specific OvensBatch Oven Optimization

Process Specific:• Designed to meet specific needs of the process• Information required for quotation:

– Size: W x H x D– Fuel Source: Natural Gas or Propane– Entry / Exit Preference: Single (SE) or Dual (D)– Door Type: – Roof Height: Exhaust Stack Length

• Additional information required:– Part Information: Size and weight– Substrate: Aluminum, Steel, Cast Iron..,.– Additional mass in oven: Cart, Conveyor rail..,.– Material Applied: Powder or Liquid Coatings

Catalog vs Process Specific OvensBatch Oven Optimization

• Additional information is used to engineer the oven to ensure efficient operation with regards to processing of batches.– Ensures burner is properly sized to raise

temperature of the part within designated time based on material specific heat variable and mass.

– Air Exchanges in oven optimized• Dry-off Oven: 6-10• Liquid Oven: 6 – 10• Powder Oven: 3 – 5• Lighter weight parts = less air changes• Heavier parts = more air changes

Definition, Specific Heat: the heat required to raise the temperature of the unit mass of a given substance by a given amount (usually one degree).

Features• UL 508a and ETL Listed• Nema 12 Enclosure• PLC Based with Touch Screen Interface• Menu driven operation• Multi-level password protection• Dynamic display of process parameters• Ability to monitor interlocks• Diagnostics and trouble shooting• Integrated VNC server allows remote

access via Ethernet

Oven Controls: PanelBatch Oven Optimization

Oven APP• View oven status remotely from any network• Emulates operator interface screen to remote

smart deviceo Current temperatureo Burner status (on/off/faulted)o Batch time remainingo Hour meterso System faultso Temperature/time log

• Includes FREE 1 year renewable subscription to receive e-mail or text notifications that includeo batch completeo oven temperature out of rangeo upcoming maintenanceo system faults


Sherwin-Williams POWDURA® Polyester (TGIC-Free & TGIC) Powder Coating

Batch Oven OptimizationAir vs Part Temperature• Manufactures of liquid and powder coating specify proper cure as “XX” time

@ “XX” part temperature.

– Part temperature can be measured and recorded using a DataPaq

– Most people do not have access to this device and do not know “part temperature”

– Remote sensing devices can be used but accuracy is in question

– Tend to bake parts longer than needed to ensure cure

– Under or over cured parts can present immediate issues or long-term performance issues.

• SmartBatch technology allows for "real-time" monitoring of part temperature.

• Incorporates part temperature probes into the design of the batch oven and control panel for monitoring part temperature during the cure process.

• The information can then be used to control cure time cycle as well as document the part curing process.

• When used in conjunction with the Col-Met SmartConnect App, you can remotely monitor part and oven temperature, batch time, system faults or out of range occurrences with Smart Deviceü Includes:All hardware and wiringü 4ea, 12’ magnetic part temperature probesü Optional 32’ length probes available, upcharge $199 each

Optional Oven Accessory (Patent Pending)


Oven Optimization:Batch Oven Optimization

• Reduce downtime by utilizing built in hour metersü SmartConnect can notify you when maintenance is due

• Most common maintenance items:ü Cleaning the UV scanner (flame sensor)ü Cleaning the flow switch sensing tubesü Cleaning the combustion fan blower wheelü Adjusting belt tensionü Bearing lubrication


• Housekeeping is importantü Keep areas around the oven clean and

unclutteredü Do no allow dust/powder to accumulate on

top of the ovenü Combustion air can be ducted outside to

extend burner life


• Periodically inspect flame condition

ü When burner is running at high fire, flame should be mostly blue with orange/yellow tips.

ü Bright yellow flame could indicate a fuel rich condition

Proper Burner Setup Improper Burner Setup


• Effects of operating a burner with improper air/fuel setupü Cracked/deteriorated mixing wingsü Gasket failuresü Heater box damageü Higher energy consumption

Burner Mixing Wings Failed Gasket Heater Box Deterioration

• What Are The Benefits: SEAL

New Product IntroductionRoll-Up Oven DoorOven Enhancement:

• Reduce oven footprint• Improved safety as operations are not exposed to

hot air while opening the oven doors

• 10 - 20% Energy savings due to less hot air leakage• Variable door height opening allowing for the

retention of more heat in the oven (energy savings)• More cure cycles per day due to ease of operation• Eliminates oven door warpage issues

New Product IntroductionRoll-Up Oven DoorOven Enhancement:


Product Information and Guides

E-Light LED Light Overview

Filter Installation Time Pad vs Blanket

SmartBatch Part Temperature

Measurement Overview

SmartConnect Oven Interface Overview

Who to Call?

Col-Met Websitewww.colmetsb.com

http://www.colmetsb.com/

New Series




Col-Met Content Available• Principles of Spray Booth Exhaust Filtration • Spray Booth Sizing and Selection• Filter Selection and Review of Case Study • Review of Common NFPA and OSHA

Requirements for Spray Booth Design• Powder Booth Selection and Considerations• Curing Solutions • Air Make-Up Unit Overview and Applications• Marketing and Sales Toolshttps://www.youtube.com/channel/UCDtFPHqayy6QfhRYQnlhSRw

https://www.youtube.com/channel/UCDtFPHqayy6QfhRYQnlhSRw

Thank-you for Joining us!

Documents

Batch Oven Optimization · well as document the part curing process. • When used in conjunction with the Col -Met SmartConnect App, you can remotely monitor part and oven temperature,