The implementation of Kairos products in pass-through surface preparation lines for powder coating is a process that should be precisely planned. Every paint shop that enters into discussions with us becomes a new challenge for us and the powder coating process is analysed by us in detail.
We ask a lot of questions and do so only to understand the situation and challenges of the paint line in question. Thanks to the care taken in the development of the implementation and our individual approach, the start-up of the process with Kairos products goes without risk to the user and without 'production surprises'. In this article, we provide details of the implementation process and discuss key aspects of the Kairos products.
Steps in the implementation of Kairos products
The implementation of Kairos products in paint shops consists of several key steps that ensure process optimisation and full customisation for the respective paint plant/line.
1. Understanding the needs and defining the scope of the project
The first step is to get to know the specifics of the paint shop in detail. By asking questions and analysing the operating conditions of the line, we identify the challenges and technological needs. This enables us to propose the best solutions to meet the customer's requirements.
2. presentation of a technical proposal
Based on the data collected, we develop a technical proposal. If necessary, we carry out laboratory tests to confirm the effectiveness of our solutions. ( Check out a selection of salt chamber tests: Salt chamber tests 1 ; Salt chamber tests 2
3. carry out process tests
The next step is technology trials on our partner's line. This is the stage that allows us to test the products under real conditions and assess their performance in practice.
4. joint validation of sample results
Together with the client, we analyse the results of the trials, assess the effectiveness and determine whether the proposed solutions meet expectations.
5. decision to implement in regular production
Once testing and validation is complete, the customer decides to implement Kairos products into daily operations.
6 Service and support
Our support does not end at the implementation stage. During operation, we provide service and ongoing support to ensure that the line operates optimally at all times.
Walk the line - pre-launch analysis
Before starting the paint line, we carry out a detailed visual inspection to assess its condition and preparation. We call this stage the 'line walk'. We check a number of key aspects, including:
- Chemical tanks and scrubbers - we assess their technical condition, level of cleanliness and potential deposits.
- Spray systems - we inspect their operation, tightness and efficiency.
- Drying temperatures - although our products can withstand temperatures above 200°C, we check that the line parameters are optimal for the process.
Step-by-step commissioning steps
The process of launching Kairos products is simple, fast and efficient. Below is a detailed walkthrough:
- Preparation of the chemical zone
Phosphate deposits must be removed to avoid them being dissolved by our products. Failure to wash thoroughly leads to unnecessary use of chemicals. - Filling the tank with water
We use ordinary process water - there is no need for demineralised water. - Heating the water to 25-27°C
Our products operate efficiently at low temperatures, which reduces energy costs. We dedicated our presentation at the 2024 Wagner Symposium to this issue. It can be viewed at this link. Wagner presentation - Addition of chemical concentrate
Add a measured amount of chemistry concentrate for surface preparation. For example, the dosage for steel is 0.5 litres of concentrate per 100 litres of water. - Concentration control
We regularly check the concentration of the chemistry and make adjustments if necessary.
- Washing the first details
If the result is satisfactory, we proceed to full production. - Start of full production
The entire process - from filling the tank with water to the start of production - lasts no more than 1.5 hours.
Key benefits of Kairos products
Kairos products are characterised by unique properties that ensure high efficiency and savings:
- No deposit formation - lines remain clean, reducing the need for frequent servicing and line downtime.
- Low operating temperature - operation at temperatures of 25-30°C significantly reduces energy consumption.
- Versatility - Our products effectively clean a variety of materials, including steel, aluminium or plastics.
- Low operating cost - no need for booster additives and extended scrubber life.
Summary
Running Kairos products on pass-through surface preparation lines is a process that brings tangible savings for any automated paint line.
Kairos products are proof that innovation can be both simple and effectiveand meet the expectations of even the most demanding customers. If you are looking for solutions to improve your paint shop, trust Kairos.
Finally, let's dispel the myths surrounding low-temperature technologies. We believe that every custodian of an automated paint line, wants to be part of the revolution, not watch from the sidelines while the competition gains the upper hand with a more efficient and cheaper to operate line.
Myths about through surface preparation lines
Over the years, many myths about low-temperature products have emerged. Misinformation is most often created and distributed, by companies who see a competitive threat in low-temperature products. Therefore, below we seek to dispel them and become 'myth busters'. We are confident in the quality of the products and the properties of the Kairos technology, which is why we are ready to carry out quality tests on any paint line of a company interested in cooperation.
Myth: Not every through line is suitable for low temperatures
Our experience shows that all lines, regardless of their age or technological advancement, can operate at low temperatures. Kairos products work well on modern installations as well as on older lines that have been in operation for many years.
Myth: Changes in the design of equipment are necessary
We make no changes to the design of the lines. Our products work with existing systems without disturbing their balance or design mass balances.
Myth: You need to balance rinsing in detail
We do not interfere with rinsing issues. As with all products and cleaning chemicals, scrubbers should be changed periodically, but from our observations, the their service life is longer than that of conventional phosphate products.
