Efficient powder coating processing

Grinding, compacting and granulating

Powder coatings are solvent-free coating substances which are used in the high-quality industrial coating of surfaces. For production, customers want a compact, space-saving and low-maintenance system that is easy to clean. Also important are wear protection and a process that is as energy-saving as possible. The end product must be a stable, dust-free granulate within the target particle size distribution. The machines and systems from Hosokawa Alpine fulfil these customer requirements perfectly. The basic functional principle of powder coating processing has remained largely unchanged since the 1960s. By optimising our grinding and classifying technologies, we have always kept pace with the increasing quality requirements.

Typical powder coating products

Epoxy resin powder coatings
Polyurethane powder coatings
Polyester powder coatings (TGIC and TGIC-free)
Hybrid powder coatings
Acrylic powder coatings
Pipe coatings

Grinding powder coatings with classifier mills from the ACM product line

The classifier mills ACM were developed to do justice to the often-voiced demand for minimal cleaning times in the production of powder coatings. The ACM EC (Easy Clean) and EC-CL (Classifier Direct Drive) are tailored to exactly these requirements. The use of the new E3 beaters achieves throughput increases of up to 20 % when compared to your current ACM classifier mill. Energy savings mean you can reduce your production costs to a minimum.

For demanding special products: high-efficiency cyclone-classifier (HECC) makes change-over from cyclone to classifier operation possible
For the dedusting of powder coatings containing titanium dioxide: TSP fine separator ensures maximum selectivity and thorough cleaning
Increase capacity and reduce energy consumption: with the new ACM impact elements (E3 beaters)

Explore more: Case Study about use of E3 beaters at Karl Bubenhofer AG

The performance factors at a glance

Larger systems available on request.
ACM	2/5	10/15	20/25	30/40	60/75
Nom. airflow [Nm³/min]	(5.5)/8.5	(15)/22.5	(30)/37.5	(45)/60	(90)/112.5
Rotor drive [kW]	3/5.5	15	22	37	55
Nominal capacity [kg/h]	Batch / 140	375	625	1,000	1,875

Larger systems available on request.

More than 600 systems installed worldwide
"Easy Clean": especially suitable in the case of frequent product changes
Processing for a host of different powder coating characteristics
Compaction of ultrafines: in-line recycling possible

ACM system for manufacturing powder coatings

with a cyclone-classifier (optional) and cyclone

ACM EC-CL

particularly easy to clean

The ACM EC (Easy Clean) was developed to meet the demands for minimum cleaning times. The mill housing is designed as a double chamber system. This means that 70 % of the parts can be easily removed for mill loading without tools.

Advantages of the new design:

Easy and quick change of the parts of the mill equipment to be cleaned
50 % time saving during cleaning
Maximum accessibility
Cooling zone to reduce product buildup
Sound reduction

E 3 Beaters: more capacity – less energy consumptionn

with the new ACM beaters

Through the use of the E3 beaters, throughput increases of up to 30 % are achieved compared to an existing ACM classifier mill. As a result of the energy savings, production costs can be significantly reduced.

The effectiveness of comminution processes is doubled in terms of high loading intensity and frequency, thanks to the novel geometry of E3 beaters. We minimise the inwards-directed stagnation point flow which hinders performance, ensuring that you benefit from the optimum exploitation of energy achieved with the new beaters. Specific energy consumption is greatly reduced as a result.

Throughput increased up to 30 %
Low fines content
Less energy consumption
Noise reduction
Wear protection

Simply have it retrofitted!

Do you already have an ACM classifier mill from Hosokawa Alpine for your powder coating production? Then you can easily have it retrofitted! The investment in the E3 Beater often pays for itself within a year. Please contact our BLUESERV service.

The cyclone classifier for efficient dedusting

change easily and flexibly

Alpine Classifier HECC

The high-efficiency cyclone classifiers (HECC) unite maximum coarse yield at efficient dedusting in classifier mode as well as optimised collection rates in cyclone mode.

Advantages of cyclone classifiers

automated lifting-swivelling device
Simple change between classifier and cyclone mode
No internal fittings and thus easy and fast cleaning

Advantages of cyclone classifiers in operation

Stepless reduction of the fines portion
Narrow particle size distribution
High precision of cut

The ultrafine classifier for maximum dedusting quality

for powder coatings containing titanium dioxide

Alpine Air Classifiert TSP

The TSP air classifier was specially designed for demanding classifying tasks. In addition to the highest selectivity, the focus was on aspects such as handling, safety as well as operating and installation costs.

All benefits at a glance

The critical fine fraction of <10 µm is <1% after the classifing process with the TSP
Product flow without back-mixing ensures a high quality of dedusting
The hinged housing enables optimal accessibility

Quick and easy cleaning when changing products minimizes downtimes
Especially suitable for toner and pigment sifting as well as for dedusting powder coatings containing titanium dioxide
Maximum precision of cut

ACM 5 NEX

with innovative protection concept for small-batch powder coating production

The new classifier mill ACM 5 NEX offers the numerous advantages of a simplified design - and is ATEX-compliant and tested for explosion protection

Pressureless design due to the avoidance of effective ignition sources
ATEX-compliant and tested for explosion protection
Tested by the European certification company Bureau Veritas: no ignition with standard powder coatings
Reduced inspection and maintenance effort
Easy cleaning and minimal downtime
Compact installation
High cost efficiency

Compacting and granulating powder coating

For increased efficiency of your production

The fine dust that is produced during the manufacturing of powder coating can be further processed with the help of compacting technology. The compaction of powder coating on roller presses enables further processing of the fine dust. This so-called inline recycling reduces waste and thus makes production more efficient.

The compaction process: dry granulation - from powder to granules

Compaction of a powder by two counter-rotating rollers
Agglomeration takes place through bonds between the particles under mechanical pressure

The process: compacting + granulation (size reduction) + sieving

The compactor is designed for compaction. During the compaction process, a high bulk density is achieved without the formation of hard particles.

The fine dust accumulated in big bags can be fed either offline or directly inline from the residual dust filter into the feed hopper of the compactor. An agitator or vibrating nozzles above the feeding screw prevent bridging of the fine dust. The horizontal auger can be equipped with a vacuum de-aeration system to increase the efficiency of the auger and the throughput of the compactor. The material is compacted into flakes in the compactor's nip. After compaction, the material is crushed by a roller crusher to the desired chip size or to granules and then fed directly into the grinding process or into big bags for further processing in the extruder.

Depending on the feed material and its particle size, different throughput rates between 80 and 150 kg can be achieved with an ARC L or K series roller press.