ZHYAO Fully Automatic Powder Coating Line Boosts Hardware Manufacturing Efficiency

ZHYAO empowers a hardware manufacturing giant to create a fully automatic powder coating line

For a long time, a well-known hardware manufacturing group has been plagued by the problems of low efficiency, uneven coating and high scrap rate of traditional manual powder spraying. To cope with the increasing market orders and enhance the competitiveness of its products, the group ultimately chose to cooperate with ZHYAO and introduced a fully automated powder coating production line. This project has become another model among the over 2,600 successful cases of ZHYAO.

This hardware group offers a wide range of products, including various types of brackets, shells, mesh parts, etc., and has very high requirements for the corrosion resistance and aesthetic appearance of the coating. After conducting in-depth on-site research, the project team of ZHYAO customized a "turnkey project" for it, which includes pretreatment (spray), automatic suspension conveying, large cyclone rapid color change powder room, powder recovery, and curing oven.

The core of the solution lies in a high degree of automation and intelligence. The fully automatic suspended conveying system precisely delivers workpieces to each processing stage according to the preset program, with a stable rhythm and eliminating the arbitrariness of manual operation. In the core spraying area, multi-axis spraying reciprocating machines have replaced manual labor, achieving 24-hour uninterrupted and precise spraying without any difference.

It is worth mentioning that in order to meet the customer's production demands for multiple varieties and colors, the quick color-changing powder room configured by ZHYAO has played a significant role. The color change time has been shortened from an average of 2 hours to less than 30 minutes, achieving a qualitative leap in production flexibility. Meanwhile, the efficient powder recovery system has significantly increased the powder feeding rate, with the comprehensive utilization rate of powder exceeding 98%, saving customers considerable raw material costs.

The data after the project went into production is encouraging: the number of workers on the entire line has been reduced from the original 12 to only one for monitoring, achieving "unmanned spraying operations on the entire line". The daily processing volume of workpieces has increased by more than 150%. The product yield rate has stabilized from about 90% previously to over 99.5%. The client's representative expressed his feelings, saying, "This production line not only resolves our bottlenecks in production capacity and quality, but its energy-saving and environmentally friendly features also give us more confidence when facing environmental protection inspections."

This case fully demonstrates the value of ZHYAO's "one-stop service" - from scheme design to installation and commissioning, the ZHYAO team provides full-process support to ensure the smooth delivery of the project and truly make customers "worry-free". At present, this production line has been operating stably for more than two years and has become a window for the group to showcase its modern manufacturing strength to the outside world.