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
Ultra-thin film powder coating
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)
For an unpressurised system design: ACM NEX series
"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:
Particularly suitable for frequent product changes
Cleaning three times faster than comparable mills or older models
E 3 Beaters: more capacity – less energy consumption
with the new ACM beaters
Through the use of the E3 beaters, throughput increases of up to 20 % 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 20 %
Low fines content
Reduction of oversized particles
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
Ultra-thin powder coating with the AFG fluidised bed opposed jet mill
Reduced consumption, increased system performance
With the AFG fluidised bed opposed jet mill, you can achieve an extremely precise and uniform particle size distribution for ultra-thin powder coatings with a d50 <10 µm and a d90 <20 µm. Producing these special fineness levels on the AFG jet mill means that the requirements of continuously advancing surface technology can be met. Thanks to the ultra-thin powder coatings, thinner powder layers can be applied with completely closed and uniform films, and at lower curing temperatures. This leads to an increase in productivity and a reduction in energy costs.
All the advantages at a glance
For thin-film powder coating applications (20–30 µm)
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 NEX
With innovative protection concept for powder coating production
The new milling systems of the ACM NEX series offer numerous advantages of a simplified design – and are ATEX-compliant and tested for explosion protection. The unique aspect about this concept: It can be created as a pressureless system by avoiding effective ignition sources. This eliminates the need for pressure shock-resistant system components as well as their annual maintenance and inspections. This enables an even more compact installation and operation of the individual system components, which in turn leads to shorter cleaning times.
Impressive advantages:
Pressureless design due to avoidance of effective ignition sources
ATEX-compliant and tested for explosion protection
Tested by the European certification company Bureau Veritas: can be used for standard and acrylic powder coatings
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 inline or offline recycling reduces waste, making your production more efficient.
The compacting process: Dry granulation – from powder to granules or chips
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. The fine dust accumulated in Big Bags can be fed into the feed hopper of the compactor either offline or directly inline from the residual dust filter. An agitator or vibration nozzles above the feeding screw prevent bridging of the fine dust. The horizontal screw can be equipped with a vacuum venting system to increase the efficiency of the screw and the throughput of the compactor. The material is compacted into flakes by two counter-rotating rollers under mechanical pressure. After compaction, it is crushed to the desired chip size or into granules by a roller crusher and then fed directly into the grinding process for further processing in the extruder.
Depending on the feed material and its particle size, different throughput rates of between 80 and 150 kg/h can be achieved with an ARC L or K series compactor.
1 Big Bag 2 Residual dust filter 3 Compactor 4 Mill 5 Extruder
Why compaction technology?
These are your advantages
Sustainability through inline recycling of fine dust
Increase in bulk density
Stable, dust-free granulate within the target particle size distribution
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