TLC Moulding Ltd. is a state of the art, 200,000 square foot facility, leading manufacturer of MDF mouldings and profiles. TLC & Cefla started their long-standing partnership almost 20years ago, with the installation of a big vacuum coating line by Delle Vedove. One year ago, Cefla gave life to a new complete high speed vacuum coating line, for TLC's new outstanding factory in Willacoochee, GA. TLC approached Cefla with a big challenge: to reach a very high level of productivity in pre-finished mouldings.
Vic De Zen is one of Canada’s most prominent entrepreneurs, chairman of Sunview Patio Doors Ltd., part of the Vision Group. A multi-armed, vertically integrated group, Vision reaches deeply into PVC building products, manufacturing, industrial/commercial land development and construction, leasing and property management, transport and hospitality. “The customer is always number one” is Vic’s mantra. He is building Vision, based on old -fashioned values and customer service.
This technology has many benefits. To start with, transfer efficiency reaches an astonishing 99%. Vacuum coaters have a limited footprint, so they occupy little factory space. Production efficiency is optimised because by using a vacuum coater, 360° sanding, coating and curing of a profile is dealt with in a single pass. Overspray is absent and the process is environmentally friendly. Coating thicknesses are high and, for example, can reach 700 µm on glass wool panels.
This is an aspect that can primarily be evaluated subjectively. However, where rigidity is a required characteristic of the coated object, this technology enables high coating layer thicknesses (e.g. 700 g/m2 in the case of ceiling tiles) by using paints with 80% solids, leading to further benefits in terms of reduced drying costs. Constant coating thickness is also a key quality achieved with vacuum coating techniques, even in the case of complex profiles.
The factors will depend on whether you are using UV-curable coating or water-based coating. UV Vacuum Coaters apply between 25 and 75 µm (1 to 3 mills) of coating per pass, whereas WB Vacuum Coaters apply between 25 and 150 µm (1 to 6 mills) of coating per pass. You will also need to consider electrical energy consumption and compressed air consumption.
Cleaning times vary according to the size of the machine and the type of paint being used. Water-based paints require less time than viscous UV lacquers. On average, when changing profiles, it will take between 10 and 15 minutes. If you are also required to change colour, this will take up to 30 minutes.
Yes. By adjusting the template opening, vacuum pressure and speed of the coating line, you can control the coating thickness, thereby affecting coating consumption. Paint viscosity is temperature-controlled in the case of UV lacquers and according to the formulation of water-based paints. This also affects overall consumption.
To make the process smoother, you can add infeed and outfeed conveyors. In any case, our solution is a fully integrated one comprising material preparation, application and drying. Edge-coating units are often installed in existing double-end tenoners for more precise workpiece guidance and consequent absence of overspray.