Junair Complete a New Powder Coating Production Line at Flogas Britain

Flogas Nov 13-098Flogas, established in 1984, are one of the leading Liquid Petroleum Gas (LPG Gas) providers, supplying Propane and Butane to domestic and industrial users across the UK. Flogas have a large number of depots nationwide enabling them to offer high quality products at a competitive price. Flogas are committed to undertaking regular reviews of their operations to identify improvements that can be made. At their site in Staveley, Flogas refurbish thousands of gas cylinders each week, these cylinders range in size, colour and weight.

In order to ensure continued operational excellence, Flogas took the decision to review its existing wet paint facility. Working with key suppliers Junair Spraybooths and Gema UK, Flogas identified that an upgrade to a new and improved powder coating paint line to include our range of powder coating equipment would offer significant advantages.

Junair Equipment offers increased efficiency and energy saving benefits

Simon Eldridge, Cylinder Supply Chain Manager for Flogas commented, “Our main objectives for the new powder coating paint line Flogas Nov 13-035was to increase the productivity and also increase the quality of our paint finish. After careful consideration and review, we decided to award Junair the contact to design, manufacture and install the new paint line. This decision was made due to the fact Junair were able to project manage the whole installation including all building works and removal of the existing paint line, however more importantly our decision rested on Junair’s proven technical ability and extensive experience in this area. Junair organised a number of site visits to their existing customers which allowed us to see the equipment we were going to be purchasing in operation also it demonstrated the quality of their equipment. The design Junair provided met all of our objectives and as with any facility improvement we worked with Junair to identify opportunities to reduce our carbon footprint and provide an enhanced working environment for our operatives”.

The new powder coating equipment paint line combines a number of processes. Once the gas cylinders have had the valves removed and undergone an internal inspection, they pass through an automated shot blasting process which removes any existing paint or debris, then the cylinders have a hot metal zinc spray automatically applied. The cylinders pass through a de-gassing oven, fueled by LPG of course. This oven heats the cylinders to over 200°C to expel any air entrained during the zinc spray process. Removing the air means that once the cylinders are painted they will be free from surface defects and provide a more robust and reliable paint finish. The cylinders are then cooled to the optimum, consistent temperature for painting.

Reduced Wastage and Paint Usage Efficiency is in Excess of 95%

Flogas Nov 13-019_retouchedThe cylinders then pass through a powder coating spray booth where powder paint is applied using automatic electrostatic spray guns.  As the bottles enter the booth a light beam sensor detects the size of the bottle allowing the reciprocators to automatically change the stroke length, and to automatically adjust the position of the fixed top and bottom spray guns to ensure full coverage.  The system can detect when there are no cylinders on the line, and this is then communicated to the spray guns so no paint is applied which reduces wastage.  The spraybooth features a plastic construction to allow maximum transfer efficiency, and has a large mono cyclone for powder recover and recycling.  Complete colour change takes around 5 minutes, and overall paint usage efficiency is in excess of 95%.

The final process is curing the coating on the cylinders.  This process uses an Infrared oven which is also powered by LPG and is controlled by an advanced touchscreen control panel.  The control allows specific cure profiles for Flogas’s different cylinder sizes, allowing each cylinder to have the optimum cure with the most efficient settings.  The oven has 12 separate heat control zones, and the control system monitors and detects any production line pauses, if the line is paused the system puts the oven into Eco mode. Once in Eco mode power is reduced to 20% to save energy and the risk of products over curing. The oven however is also responsive enough so that once the line is back up and running the oven is ready go within 30 seconds.

Adjustable Overhead Conveyor Systems to Optimise Paint Application and Curing

Due to the weight and size of the cylinders a continuously moving overhead conveyor system transports the cylinders through the complete paint process.  The conveyor system incorporates adjustable speed rotation in the paint booth and ovens to optimise the paint application and curing.  The system will be handling up to 4 tonnes of product every hour.  Using an overhead conveyor system also maximises the facilities floor space.  A powered manipulator arm assists workers to maneuver the cylinders on and off the overhead conveyor systems.

What Simon at Flogas had to Say about the Spray Booth Service and Equipment from Junair

Simon also commented “We are delighted with the results of our new paint line. We have seen an overall cost reduction achieved by reduced paint costs, a reduction in maintenance costs as the new equipment is much more reliable and also a reduction in the amount of labour required on the production line. The new powder coating spray booth gives the cylinders a much improved surface finish, and is also more reliable than the previous wet paint spraybooth. Throughout the complete installation Junair managed the whole process from start to finish. We were able to lean on their in-house expertise to ensure the project was completed to the highest standard, to specification and on time. I would have no hesitation in recommending Junair”.

Written by

Direct Line Group install SiriusLED

With vehicles coming and going all day long, body shop lighting issues are the last thing you need. A problem that Dean Kelly, Technical Services Manager for the Direct Line Group knows all too well. The Solution Direct Line Group have recently acquired the Junair Sirius LED system for their Weybridge Bodyshop, and have installed […]

Read More

Maximum impact for Alan Reed Ltd with the SiriusLED lighting system

Need some help designing your new build workshop? Not sure what lighting system to use? Accident repair company, Alan Reed Ltd in Shildon, County Durham have recently integrated Junair’s new SiriusLED lighting system into their new build workshop facility and have been over the moon with the results. Being tasked with the total fit out […]

Read More

Junair helps H Samson (Bolton) Ltd drive output and lower running costs

The accident repair, servicing and MOT experts H Samson (Bolton) Ltd got in touch with the team at Junair Spraybooths to discuss potential work on upgrading their existing setup. Suffice to say that we were excited to get started. Here’s how the project happened… Who are H Samson (Bolton) Ltd? Established for over 70 years, […]

Read More

Junair proudly supply Liquidwrap Ltd. with one of our high quality Spraybooth ovens!

Recently, the spraybooth and paint finishing experts here at Junair were contacted by the team at Liquidwrap Ltd. after they had moved into a new head office in London, and required our assistance with the transition. In our latest post, we talk through exactly how we were able to help Liquidwrap and also provide information […]

Read More

World-class marine outfitter purchases state-of-the-art manufacturing systems from Junair

Trimline are global experts in the interior refurbishment of marine vehicles with prestigious clients such as Cunard, Royal Navy, BAE Systems and Princess Cruises. The quality of the finish they provide is paramount to their ongoing success, and as the refinishing area is part of the factory tour for new and prospective clients, the aesthetics […]

Read More

Body Shop Spray Booth Installed

Award-winning body shop chain, AW Repair Group, chosen Junair once again to replace existing paintbooth operations. Having installed a Junair 3 Series at their last two new ventures, Junair Spraybooths have seen an increase in throughput and decrease in costs as they embarked on a complete strategic replacement programme. Quality Spraybooths for Body Shops The Sleaford, […]

Read More

Paul Cox Panel and Paint relocate to Wellingborough

Paul Cox Panel and Paint are an accident repair centre based in Wellingborough, having recently relocated from Northampton. Established in 2003, their aim is to carry out high quality repairs to all car body types. Recognising a niche in the market, Paul Cox have now also opened a specialist coatings department, enabling them to paint […]

Read More

Junair install new spraybooth equipment for NCR Bodyshops

NCR Bodyshops operate a group of bodyshops in the South of England offering the very best in vehicle care since 1986. After recognising a need for more repairers in the area, the business opened a new site in Swindon. New SprayBooth equipment for NCR Bodyshops Junair pride themselves on taking the time to understand a […]

Read More

New Paintshop for Protek Bathgate Ltd

Protek Bathgate Ltd is a family run accident repair business with over 40 years’ experience. Founded in 1974, it has gained the recommendations of several leading insurance companies and also the BSI Kitemark accreditation, it’s clear Protek are focused on the highest standard of body repair and the highest standard of paint finishes, so when […]

Read More
Blog

Read our latest news and insights from around the spray booth industry.

Find out more
Case Studies

Read about some of our latest client projects.

Find out more
Downloads

Take a look at some of our downloadable resources.

Find out more

If you have a new project that you would like some help with, call us on +44 1706 363 555 to speak to a member of our team about your requirements. We will take you through our project process step-by-step, whether you are redeveloping an existing site or building a new facility, Junair can help.