Drying Oven

The drying oven is equipped with a heat generator that heats the air inside the chamber to the desired temperature, thus drying liquid paint or curing powder paint.

The ovens are equipped with a heat generator that can be either direct or indirect exchange, which allows the desired temperature to be reached within the baking or drying chamber. Pieces coming from other stages of processing, such as washing or painting, are fed into the oven via an overhead conveyor or other means of transport.

The temperature inside the oven is reached and maintained at a constant setpoint throughout the baking cycle, thanks to a temperature regulator located in the electrical panel and a temperature probe inserted inside the baking chamber. EMS drying and curing ovens can reach a maximum temperature of 350°.

Our standard curing and drying ovens have a temperature range of + or – 2°C. For the aeronautic industry or other critical application areas, we can narrow the range down to + or – 0.5°C.

Powder coating is increasingly accepted as the preferred finishing process for many applications. Increasingly stringent environmental regulations, rising costs in all areas, and demands by consumers for better quality and more durable products are among the challenges facing today’s finishers. Powder coatings provide a solution to these challenges and others. Powder coating is the technique of applying dry paint to the component.

The powdered paint is normally applied by using a powder feed system and gun to electrostatically charge and spray the powder onto the part. For some applications, the part being coated is dipped into a fluidized bed of powder. The coated part is then heated in an oven, or via infrared panels, to melt and cure the paint. During the curing process, a chemical cross-linking reaction is triggered and it is this chemical reaction that gives the powder coatings many of their desirable properties.

Drying Oven for Powder Coating

A drying oven for powder coating, also known as a curing oven, is a crucial piece of equipment in the powder coating process. It is responsible for heating and curing the powder coating, ensuring that it adheres properly to the surface and forms a durable, long-lasting finish.

A drying oven, also known as a curing oven, is an essential component in the powder coating process. It plays a crucial role in transforming the applied powder coating into a durable and long-lasting finish. The oven’s primary function is to melt and fuse the powder particles onto the substrate, creating a uniform, protective layer.

Types of Drying Ovens for Powder Coating

There are two main types of drying ovens commonly used in powder coating applications:

1. Convection Ovens: These ovens circulate hot air around the workpiece, evenly distributing heat and promoting uniform curing. Convection ovens are suitable for parts with consistent shapes and surfaces.
2. Infrared (IR) Ovens: IR ovens utilize electromagnetic radiation to directly heat the workpiece, allowing for faster curing times and reduced energy consumption. IR ovens are particularly effective for complex-shaped parts or those made from materials with poor heat conductivity.

Components of a Drying Oven

Regardless of the type, a drying oven typically consists of the following components:

1. Heating Elements: Nichrome ribbons, ceramic elements, or infrared emitters provide the necessary heat for curing the powder.
2. Air Circulation System: Fans or blowers circulate hot air within the oven chamber, ensuring even heat distribution and consistent curing.
3. Temperature Control System: A temperature controller monitors and regulates the oven temperature, ensuring optimal curing conditions.
4. Safety Features: Over-temperature shut-offs, emergency stop buttons, and ventilation systems safeguard the user and prevent potential hazards.

Factors to Consider When Choosing a Drying Oven

Several factors influence the selection of an appropriate drying oven for powder coating applications:

1. Size and Shape of Workpieces: The oven’s size should accommodate the largest parts you intend to coat.
2. Production Volume: Batch ovens are suitable for low-volume production, while conveyor ovens are designed for high-volume applications.
3. Desired Finish: Convection ovens are ideal for general-purpose applications, while IR ovens are preferred for high-gloss finishes or heat-sensitive materials.
4. Budget: Drying ovens vary in price based on size, features, and brand.

Additional Considerations for Powder Coating

1. Ventilation: Proper ventilation is essential to remove fumes and dust generated during the powder coating process.
2. Pretreatment: The substrate must be adequately pretreated to ensure proper adhesion of the powder coating.
3. Powder Application: Powder can be applied using various methods, such as electrostatic spray, fluidized bed dipping, or electrostatic deposition.
4. Curing Parameters: The curing temperature, time, and atmosphere influence the final properties of the powder coating finish.
5. Quality Control: Regular inspection and testing are crucial to ensure consistent and high-quality powder coating results.

Conclusion

Drying ovens play a vital role in the powder coating process, transforming the applied powder into a durable and aesthetically pleasing finish. By carefully selecting the appropriate oven and implementing proper powder coating techniques, manufacturers can achieve high-quality results that enhance the appearance and longevity of their products.

Purpose of Drying Ovens in Powder Coating

Drying ovens, also known as curing ovens, play a crucial role in the powder coating process, transforming the applied powder coating into a durable and long-lasting finish. They serve several essential purposes:

1. Melting and Fusing Powder Particles:

The primary function of a drying oven is to melt and fuse the powder particles onto the substrate, creating a uniform, protective layer. This process, known as curing, involves heating the powder to a specific temperature for a predetermined time. During curing, the powder particles melt, flow, and crosslink, forming a strong, cohesive film.

2. Enhancing Adhesion:

Proper curing ensures that the powder coating adheres firmly to the substrate, preventing peeling or delamination. The heat and time applied in the drying oven promote the formation of mechanical and chemical bonds between the powder coating and the substrate, resulting in a durable and long-lasting finish.

3. Achieving Desired Finish:

The curing process significantly influences the final appearance and properties of the powder coating finish. By carefully controlling the curing temperature, time, and atmosphere, manufacturers can achieve various desired finishes, ranging from smooth and glossy to textured and matte.

4. Enhancing Physical Properties:

Curing enhances the physical properties of the powder coating finish, making it resistant to scratches, abrasions, chemicals, and environmental factors. The heat and time applied in the drying oven promote the crosslinking of polymer chains within the powder coating, leading to a tougher, more durable finish.

5. Ensuring Consistent Results:

Drying ovens provide a controlled environment for curing, ensuring consistent and reproducible results. The precise temperature control and uniform heat distribution within the oven minimize variations in the curing process, resulting in a consistent finish quality across different batches of parts.

After the powder is sprayed onto the surface, it needs to be cured to solidify and form a durable coating. This is where a drying oven comes into play. The oven heats the powder to a specific temperature for a predetermined amount of time, causing the powder particles to melt and fuse together, creating a solid film.

Types of Drying Ovens for Powder Coating

There are two main types of drying ovens for powder coating:

1. Batch ovens: Batch ovens are typically used for smaller batches of workpieces. They have a fixed chamber size, and the workpieces are loaded and unloaded manually.
2. Conveyorized ovens: Conveyorized ovens are designed for high-volume production. They have a continuous conveyor that moves the workpieces through the oven, ensuring consistent curing and uniform results.

Factors to Consider When Choosing a Drying Oven

When choosing a drying oven for powder coating, several factors need to be considered:

1. Workpiece size and volume: The size of the oven should be appropriate for the size and volume of the workpieces you typically coat.
2. Curing temperature and time requirements: The oven should be able to reach the specific temperature and hold it for the required time for the powder coating to cure properly.
3. Ventilation and fume control: The oven should have proper ventilation and fume control systems to remove harmful fumes and maintain a safe working environment.
4. Energy efficiency: Consider the energy efficiency of the oven to minimize operating costs.
5. Ease of operation and maintenance: The oven should be easy to operate and maintain to ensure optimal performance and longevity.

Maintaining a Drying Oven for Powder Coating

Regular maintenance of the drying oven is essential to ensure its optimal performance and longevity. This includes:

1. Cleaning the oven chamber regularly: Remove any debris or powder buildup to prevent contamination and ensure proper airflow.
2. Inspecting the heating elements and fans: Ensure the heating elements are functioning properly and the fans are providing adequate airflow.
3. Calibrating the temperature controls: Regularly check and calibrate the temperature controls to ensure accurate curing temperatures.
4. Replacing worn-out parts: Replace any worn-out or damaged parts promptly to maintain the oven’s efficiency and safety.

Conclusion

Drying ovens are essential components of powder coating systems, ensuring the proper curing and adhesion of powder coatings. By choosing the right oven and maintaining it properly, you can achieve consistent, high-quality results while minimizing downtime and operating costs.

Customized drying and curing ovens

Customized drying and curing ovens are designed to meet specific requirements for drying and curing processes in various industries. These ovens offer flexibility in terms of size, temperature range, airflow patterns, and control systems to cater to diverse applications.

Applications of Customized Drying and Curing Ovens

Customized drying and curing ovens find applications in a wide range of industries, including:

• Pharmaceutical: Drying and curing of pharmaceutical products, such as tablets, capsules, and granules, to ensure their stability and effectiveness.
• Food processing: Drying and curing of food products, such as fruits, vegetables, and meat, to extend their shelf life and enhance their flavor and texture.
• Chemical processing: Drying and curing of chemical compounds, such as catalysts, resins, and pigments, to achieve desired properties and ensure safe handling.
• Electronics manufacturing: Drying and curing of electronic components, such as circuit boards and semiconductors, to remove moisture and prevent corrosion.
• Automotive industry: Drying and curing of painted car parts and other components to achieve a durable and high-quality finish.

Benefits of Customized Drying and Curing Ovens

Customized drying and curing ovens offer several advantages over standard ovens, including:

• Tailored Design: They are specifically designed to meet the unique requirements of the application, ensuring optimal performance and efficiency.
• Precise Temperature Control: They provide precise temperature control, allowing for consistent and accurate curing of materials.
• Controlled Airflow Patterns: They offer controlled airflow patterns to ensure uniform drying and curing throughout the oven chamber.
• Advanced Control Systems: They incorporate advanced control systems for monitoring and managing the drying and curing process.
• Integration with Production Lines: They can be seamlessly integrated into existing production lines for streamlined production processes.

Considerations for Choosing Customized Drying and Curing Ovens

When selecting a customized drying and curing oven, several factors should be considered:

• Material Properties: The properties of the material being dried or cured, such as its moisture content, heat sensitivity, and desired final state.
• Production Volume: The volume of material to be processed and the required production rate.
• Space Availability: The available space for installing the oven and the desired level of automation.
• Budget: The overall budget for the oven and any additional equipment or accessories.
• Environmental Regulations: Compliance with environmental regulations related to emissions and energy efficiency.

Conclusion

Customized drying and curing ovens play a critical role in various industries by ensuring the consistent and high-quality drying and curing of materials. By carefully considering the specific needs of the application and selecting the appropriate oven design, companies can optimize their processes, enhance product quality, and improve overall efficiency.

EMS manufactures custom drying and curing ovens in order to solve any problem related to drying and curing objects of any size.

Our ovens are designed and built according to your actual dimensional, technological, process, or production requirements. In fact, EMS Powder Coating Quipment realizes baking and drying ovens that can be customized in size and shape (in case of space problems) and can have:

• 2 or 4 shutter-equipped closing portals with sliding doors,
• side doors,
• portholes with internal lighting,
• graphic recorder with several temperature probes,
• stainless steel inner chamber,
• and other features according to your specific needs.

Energy-saving and heat recovery systems

Ovens are composed of a heat generator inside which there is a burner, generally gas-fired. The latter heats the air taken from the baking chamber through an aspirator which then feeds it back into the oven’s plenum. Here the air is mixed and introduced, from the top to the bottom, inside the treatment chamber.

In EMS ovens, the hot air inside the baking chamber is constantly recirculated.  This solution allows you to keep the temperature constant over time with the minimum possible energy consumption while also ensuring an even distribution of the air at the same time.

Moreover, at the end of the firing cycle, in order to allow the pieces to be unloaded from the oven, an aspirator moves the hot air outside, which can be then used to feed a heat recovery unit.

The insulation of the ovens is realized with high-density mineral wool, whose thickness varies from 50 to 150 mm according to the temperatures to be reached during the expected working cycle. Eurotherm’s particular construction technology without thermal bridges guarantees an effective barrier against heat dispersion as well as considerable energy saving.

Drying oven with airstream combustion (direct exchange)

An airstream combustion (direct exchange) drying oven is a type of drying oven that uses a burner to heat an airstream, which is then passed over the surface of the material to be dried. The heat from the airstream evaporates the moisture from the material, leaving it dry.

Advantages of airstream combustion (direct exchange) drying ovens:

• High efficiency: Airstream combustion ovens are very efficient at drying materials. The direct exchange of heat between the airstream and the material being dried results in a rapid transfer of heat, which quickly evaporates the moisture from the material.
• Good control over the drying process: Airstream combustion ovens provide good control over the drying process. The temperature of the airstream can be precisely controlled, and the airflow can be adjusted to achieve the desired drying rate.
• Suitable for a wide range of materials: Airstream combustion ovens can be used to dry a wide range of materials, including metals, plastics, and textiles.
• Compact design: Airstream combustion ovens are relatively compact in size, making them a good choice for applications where space is limited.

Disadvantages of airstream combustion (direct exchange) drying ovens:

• Higher emissions: Airstream combustion ovens produce higher emissions than other types of drying ovens, such as infrared or vacuum ovens. This is because the burner produces combustion gases, which are then released into the atmosphere.
• Higher operating costs: Airstream combustion ovens are more expensive to operate than other types of drying ovens. This is because they require fuel to operate the burner.

Applications of airstream combustion (direct exchange) drying ovens:

Airstream combustion ovens are commonly used in a variety of industries, including:

• Automotive: Drying of painted car parts and other components.
• Pharmaceutical: Drying and curing of pharmaceutical products, such as tablets, capsules, and granules.
• Food processing: Drying and curing of food products, such as fruits, vegetables, and meat.
• Chemical processing: Drying and curing of chemical compounds, such as catalysts, resins, and pigments.
• Electronics manufacturing: Drying and curing of electronic components, such as circuit boards and semiconductors.

Conclusion:

Airstream combustion (direct exchange) drying ovens are a versatile and efficient type of drying oven that can be used to dry a wide range of materials. They are a good choice for applications where high efficiency, good control over the drying process, and a compact design are important. However, it is important to consider the higher emissions and operating costs associated with these ovens.

Here are some additional tips for using an airstream combustion (direct exchange) drying oven:

• Ensure that the oven is properly ventilated to remove combustion gases.
• Monitor the temperature of the airstream to ensure that it is not too high for the material being dried.
• Adjust the airflow to achieve the desired drying rate.
• Regularly clean and maintain the oven to prevent the buildup of dust and debris.

By following these tips, you can help to ensure that your airstream combustion (direct exchange) drying oven is operating properly and efficiently.

In ovens with airstream combustion, the burner flame is in direct contact with the air within the cooking chamber. For this reason, it is most suitable for baking powder coatings (polymerization) and water-based liquid coatings.

The main advantages of using an oven with airstream combustion are:

• Affordability of the operation.
• Speed of reaching the designated temperature.

The main sources of fuelling are methane gas, LPG, and diesel.

Drying Oven

The dipping type surface pretreatment process requires a fast drying operation after the chemical process to have good paint quality. Materials dry within 10-12 minutes by drying oven. Circulation canals and airflow is designed to have a fast, regular and economic drying operation.

The drying degree should not be over 125°C to save the phosphate covered on the material. The ideal temperature is between 100-110°C. The drying oven has been designed and produced by EMS Powder Coating Equipment. so as to increase the temperature to 120°C within 35-40 minutes.

Technical Specifications of a Drying Oven

The technical specifications of a drying oven can vary depending on the type of oven, its intended application, and the manufacturer. However, some common technical specifications for drying ovens include:

Temperature Range: The temperature range of a drying oven is the minimum and maximum temperatures that the oven can achieve. The temperature range should be appropriate for the material being dried. For example, ovens used to dry food products typically have a lower temperature range than ovens used to cure powder coatings.

Airflow Rate: The airflow rate of a drying oven is the volume of air that is circulated through the oven chamber per unit of time. The airflow rate should be high enough to ensure that the material being dried is evenly exposed to the heated air. However, the airflow rate should not be too high, as this can cause the material to be damaged.

Chamber Size: The chamber size of a drying oven is the internal dimensions of the oven chamber. The chamber size should be large enough to accommodate the material being dried. However, the chamber size should not be too large, as this can waste energy.

Control System: The control system of a drying oven allows the user to set and monitor the temperature, airflow rate, and other parameters of the drying process. The control system should be easy to use and understand.

Power Consumption: The power consumption of a drying oven is the amount of electricity that the oven consumes per unit of time. The power consumption should be considered when choosing an oven, as it can affect the operating costs of the oven.

Additional Technical Specifications:

• Heating Method: The heating method of a drying oven is the method used to heat the air in the oven chamber. Common heating methods include electrical resistance heating, hot air combustion, and infrared heating.
• Ventilation System: The ventilation system of a drying oven removes moisture and fumes from the oven chamber. The ventilation system should be adequate to prevent the buildup of moisture and fumes.
• Safety Features: Drying ovens should have safety features to protect the user from hazards such as burns and fires. Common safety features include thermal overload protection, door interlocks, and emergency stop buttons.

It is important to consult with the manufacturer of a drying oven to obtain the specific technical specifications for the oven. This will ensure that the oven is suitable for the intended application and that it meets all safety requirements.

• Heating type: With thermocouple, closed air circulation, indirect heating
• Heating Capacity: Calculated according to the capacity of the project
• Circulation fans : 3 Pieces x 4 kW Ø560
• Burner: Uret (Made in Turkey)
• Insulation: 150 mm.
• Air Curtains : 2 units x 3 kW = 6 kW
• Exhaust fan : 0,55 kW

Oven Body

The oven body is the main structural component of an oven. It houses the heating elements, fans, controls, and other components that make the oven function. The oven body is typically made of metal, such as stainless steel or aluminum, and it is designed to be durable and heat-resistant.

The oven body is typically insulated with a material such as fiberglass or rockwool to prevent heat from escaping the oven. The insulation also helps to protect the oven body from warping or damage from heat.

The oven body has a number of openings that allow air to circulate inside the oven. These openings also allow for the escape of moisture and fumes from the oven.

The oven body is typically mounted on a stand or frame. The stand or frame provides support for the oven body and prevents it from tipping over.

The oven body is a critical component of an oven and it plays an important role in the oven’s performance and safety.

Here are some additional tips for maintaining an oven body:

• Clean the oven body regularly to remove grease and food splatters.
• Inspect the oven body regularly for signs of damage, such as dents or cracks.
• Do not use abrasive cleaners on the oven body.
• Do not overload the oven with food.
• Follow the manufacturer’s instructions for cleaning and maintaining the oven body.

By following these tips, you can help to extend the lifespan of your oven body and ensure that it continues to function properly.

The outside surface of the oven’s body is galvanized (powder painted); the inner side has been made of galvanized sheet metal, and have isolated with 150 mm Rockwool and 100 mm Glasswool, compressed into 150 mm of isolation. Panels of sandwich-shaped ovens are attached to each other with high heat resistant silicone

The Heating Unit of the Drying Oven

The heating unit of the drying oven is the component responsible for generating heat to dry the material inside the oven chamber. The specific type of heating unit used in a drying oven will depend on the application and the desired drying temperature.

Types of Heating Units

Common types of heating units used in drying ovens include:

1. Electrical Resistance Heating: Electrical resistance heating elements are the most common type of heating unit used in drying ovens. These elements consist of a wire or coil of metal that is heated when an electric current is passed through it. Electrical resistance heating elements are efficient and easy to control.
2. Hot Air Combustion: Hot air combustion heating units use a burner to heat a stream of air. The heated air is then circulated through the oven chamber. Hot air combustion heating units are effective at drying materials that are not sensitive to heat or moisture.
3. Infrared Heating: Infrared heating units use infrared radiation to heat the material being dried. Infrared radiation is a form of electromagnetic radiation that is similar to visible light, but with longer wavelengths. Infrared radiation can be absorbed by materials, causing them to heat up. Infrared heating units are efficient and can be used to dry a wide range of materials.

Factors Affecting the Choice of Heating Unit

When choosing a heating unit for a drying oven, several factors should be considered:

1. Drying Temperature: The desired drying temperature will determine the type of heating unit that is required. For example, electrical resistance heating elements are typically used for drying materials at temperatures below 400°C, while hot air combustion heating units can be used for drying materials at temperatures up to 1000°C.
2. Material Sensitivity: The sensitivity of the material being dried to heat and moisture should also be considered. For example, infrared heating units are a good choice for drying materials that are sensitive to moisture, as they do not require direct contact with the material.
3. Energy Efficiency: The energy efficiency of the heating unit should also be considered. Electrical resistance heating elements are typically the most energy-efficient type of heating unit, followed by hot air combustion heating units and then infrared heating units.
4. Cost: The cost of the heating unit should also be considered. Electrical resistance heating elements are typically the least expensive type of heating unit, followed by hot air combustion heating units and then infrared heating units.

Conclusion

The heating unit is a critical component of a drying oven and it plays a major role in the oven’s performance and efficiency. By carefully considering the factors affecting the choice of heating unit, you can select the right heating unit for your specific application and drying needs.

Here are some additional tips for maintaining the heating unit of a drying oven:

• Clean the heating unit regularly to remove dust and debris.
• Inspect the heating unit regularly for signs of damage, such as cracks or breaks.
• Do not overload the oven with material.
• Follow the manufacturer’s instructions for cleaning and maintaining the heating unit.
• Have the heating unit serviced by a qualified technician on a regular basis.

By following these tips, you can help to extend the lifespan of the heating unit and ensure that it continues to function properly.

The heating unit’s capacity makes it able to increase the heat of the oven to 120 ºC. The firing room of the heat exchanger is made of AISI 310S quality stainless steel and its pipe sheaves are made of normalized caldron pipe. The body of the heating unit is isolated with150 mm Rockwool. Hot dry air prepared in the heating unit will be homogeneously distributed inside the oven with help of adjustable air canals which are made of galvanized sheet metal.

The Circulation Fan of the Drying Oven

The circulation fan of a drying oven is a crucial component that ensures the efficient and uniform distribution of heat throughout the oven chamber. It plays a vital role in the drying process by actively circulating the heated air around the material being dried, facilitating the transfer of heat and accelerating the evaporation of moisture.

Types of Circulation Fans

There are two main types of circulation fans commonly used in drying ovens:

1. Axial Flow Fans: Axial flow fans are the most common type of fan used in drying ovens. They consist of a propeller-like blade assembly that rotates along the axis of the fan, pushing air in a straight line along the fan’s axis. Axial flow fans are efficient and effective at circulating air in enclosed spaces like oven chambers.
2. Centrifugal Fans: Centrifugal fans are less common in drying ovens but are sometimes used for applications requiring high airflow rates or high pressure. They consist of a rotating impeller that draws air in at the center and expels it radially outward. Centrifugal fans are more powerful than axial flow fans but can be less efficient.

Importance of Circulation Fans in Drying Ovens

Proper circulation of heated air is essential for efficient and uniform drying. The circulation fan helps to:

1. Prevent Stratification: Without adequate circulation, heated air tends to rise and concentrate at the top of the oven chamber, while cooler air remains at the bottom. This stratification leads to uneven drying, with the top of the material drying faster than the bottom.
2. Increase Heat Transfer: The circulation fan promotes the movement of heated air around the material, increasing the surface area exposed to heat. This enhances the rate of heat transfer and accelerates the evaporation of moisture from the material.
3. Prevent Hot Spots: The circulation fan helps to distribute heat evenly throughout the oven chamber, preventing the formation of hot spots that could damage the material.
4. Remove Moisture: The circulation fan also helps to remove moisture-laden air from the oven chamber, preventing the buildup of humidity that could hinder the drying process.

Selection and Maintenance of Circulation Fans

The choice of circulation fan depends on the specific requirements of the drying oven and the material being dried. Factors to consider include:

1. Airflow Rate: The airflow rate determines the volume of air circulated per unit of time. A higher airflow rate is generally required for faster drying or for larger oven chambers.
2. Static Pressure: Static pressure refers to the fan’s ability to overcome resistance to airflow, such as that caused by filters or ducts. A higher static pressure is required for ovens with filters or longer ductwork.
3. Noise Level: Noise level is an important consideration for ovens located in noise-sensitive environments. Axial flow fans tend to be quieter than centrifugal fans.
4. Durability: The fan should be able to withstand the high temperatures and continuous operation required in drying ovens.

Regular maintenance of the circulation fan is essential for optimal performance and longevity. This includes:

1. Cleaning: Regularly clean the fan blades and housing to remove dust and debris that could impede airflow.
2. Lubrication: Lubricate the fan bearings according to the manufacturer’s instructions to ensure smooth operation and reduce wear.
3. Inspection: Inspect the fan regularly for signs of damage, such as cracks, loose wires, or worn bearings.
4. Replacement: Replace worn-out or damaged fan components promptly to maintain proper airflow and prevent further damage.

Conclusion

The circulation fan plays a crucial role in ensuring the efficient and uniform drying of materials in drying ovens. By selecting the right fan and maintaining it properly, you can optimize the drying process, achieve consistent results, and extend the lifespan of your drying oven.

The circulation fan provides circulation of the air and it is produced as a directly coupled heating option. The hot air sucked from inside of the oven passes through the heating exchanger and moves through blowing channels.

• Fan Type: Direct Coupled
• Motor Power: Calculated according to the project capacity
• Cooling Fan: Aluminium Casting

Air Curtains of the Drying Oven

Air curtains, also known as air barriers, are an important component of many drying ovens, particularly those used in industrial applications. They provide a number of benefits, including:

1. Reducing Heat Loss: Air curtains create a barrier of air that prevents hot air from escaping the oven chamber. This helps to maintain a consistent temperature inside the oven, reducing energy consumption and improving drying efficiency.

2. Preventing Contamination: Air curtains can help to prevent airborne contaminants, such as dust, debris, and insects, from entering the oven chamber. This is especially important for industries that require high levels of product cleanliness, such as pharmaceuticals and food processing.

3. Improving Drying Uniformity: Air curtains help to distribute heated air evenly throughout the oven chamber, preventing the formation of hot spots or cold spots. This contributes to more uniform drying and consistent product quality.

4. Protecting Workers from Heat and Fumes: Air curtains can help to protect workers from exposure to hot air and fumes that may be emitted from the oven. This can improve workplace safety and reduce the risk of heat-related illnesses.

5. Enhancing the Appearance of the Oven: Air curtains can add a polished and professional look to the oven, making it more aesthetically pleasing and integrated into the overall workspace.

Types of Air Curtains

There are two main types of air curtains commonly used in drying ovens:

1. Ambient Air Curtains: Ambient air curtains draw in air from the surrounding environment and direct it across the oven opening. These curtains are relatively simple and inexpensive, but they may not be as effective in preventing heat loss or contamination.
2. Filtered Air Curtains: Filtered air curtains utilize a filtered air supply to create a cleaner and more controlled air barrier. These curtains are more effective in preventing contamination and improving drying uniformity, but they are also more expensive than ambient air curtains.

Selection and Maintenance of Air Curtains

The choice of air curtain depends on the specific requirements of the drying oven and the application. Factors to consider include:

1. Airflow Rate: The airflow rate determines the volume of air circulated across the oven opening. A higher airflow rate is generally required for larger oven openings or for applications where contamination prevention is critical.
2. Airflow Velocity: The airflow velocity determines the speed of the air stream exiting the curtain. A higher airflow velocity is more effective in preventing hot air escape and minimizing contamination ingress.
3. Filtration Level: The level of filtration required depends on the level of contamination prevention needed. For applications requiring high cleanliness, HEPA or ULPA filters should be used.
4. Mounting Options: Air curtains can be mounted on the top, sides, or bottom of the oven opening, depending on the specific design of the oven and the desired airflow pattern.
5. Control System: Some air curtains include a control system that allows for adjusting the airflow rate, airflow velocity, and filtration settings.

Regular maintenance of the air curtain is essential for optimal performance and longevity. This includes:

1. Cleaning: Regularly clean the air intake filter to prevent dust and debris buildup, which can reduce airflow and affect filtration efficiency.
2. Inspection: Inspect the air curtain regularly for signs of damage, such as cracks, loose wires, or worn components.
3. Replacement: Replace worn-out or damaged components promptly to maintain proper airflow and prevent further damage.

Conclusion

Air curtains are valuable components of drying ovens, offering a range of benefits that enhance the efficiency, safety, and overall performance of the drying process. By carefully selecting the appropriate air curtain and maintaining it properly, you can optimize your drying operations and achieve consistent, high-quality results.

Thanks to the air curtains in the oven inlet and outlet, minimizing the temperature loss was provided. The air circulation is underway through the fans each of which has a flow of 4.000 m3 / h, and the leakage of the hot air is blocked. The channels of air curtains and air pockets were made of 1.5 mm of galvanized metal sheet.

Air Curtain Fans
Fan Type: Direct coupled
Power: Calculated according to the project capacity
Cooling fan: Aluminium Casting

Exhaust Fan of the Drying Oven

It’s made for throwing out the gases that may come out during curing operations. The exhaust fan is able to be continually operated from the control panel, also its operating and stopping periods could be made automatically by adjusting from the control panel.

• Exhaust Fan
• Fan Type: Direct coupled
• Motor Power: Calculated according to the project capacity

Digital Thermal Controller (Digital Thermostat)

A digital thermal controller, also known as a digital thermostat, is an electronic device that is used to control the temperature of a heating or cooling system. It is a more advanced and precise version of a traditional thermostat, which uses a mechanical switch to control the flow of electricity to the heating or cooling system.

How Digital Thermal Controllers Work

Digital thermal controllers use a sensor to measure the temperature of the environment around it. The sensor sends this information to a microprocessor, which then compares it to the setpoint temperature that has been entered by the user. If the temperature is below the setpoint, the microprocessor will send a signal to the heating system to turn on. If the temperature is above the setpoint, the microprocessor will send a signal to the cooling system to turn on.

Digital thermal controllers are more accurate than traditional thermostats because they use a sensor to measure the temperature directly. This eliminates the need for a bimetallic coil, which can be affected by changes in humidity. Digital thermal controllers are also more precise than traditional thermostats because they allow the user to set the temperature to within one degree of accuracy.

Benefits of Digital Thermal Controllers

There are several benefits to using a digital thermal controller, including:

• Accuracy: Digital thermal controllers are more accurate than traditional thermostats, which can help to save energy.
• Precision: Digital thermal controllers allow the user to set the temperature to within one degree of accuracy, which can help to improve comfort.
• Programmability: Many digital thermal controllers can be programmed to turn on and off at specific times of the day, which can help to save energy and improve comfort.
• Ease of use: Digital thermal controllers are easy to use and understand, even for people who are not familiar with electronics.

Applications of Digital Thermal Controllers

Digital thermal controllers are used in a wide variety of applications, including:

• Home heating and cooling systems
• Industrial heating and cooling systems
• Refrigeration and freezing systems
• Incubators
• Greenhouses

Choosing a Digital Thermal Controller

When choosing a digital thermal controller, there are several factors to consider, including:

• Accuracy: The accuracy of the controller is important for applications where temperature control is critical.
• Precision: The precision of the controller is important for applications where temperature control needs to be very precise.
• Programmability: The programmability of the controller is important for applications where temperature control needs to be automated.
• Ease of use: The ease of use of the controller is important for applications where the controller will be used by people who are not familiar with electronics.
• Price: The price of the controller is an important factor for all applications.

Conclusion

Digital thermal controllers are a versatile and effective way to control the temperature of a heating or cooling system. They are more accurate, precise, and programmable than traditional thermostats, and they can be used in a wide variety of applications. When choosing a digital thermal controller, it is important to consider the accuracy, precision, programmability, ease of use, and price of the controller.

Blow settings can be adjusted through a digital thermostat:

1. Operating Temperature:
   The temperature check is carried out through the digital thermostat; the thermostat can be adjusted at the desired temperature, and the burner operates automatically according to the adjusted temperature.

2. Operating Break:
   The operating break of the burner ( For example 2°C ) is adjusted; when the oven temperature decreased to the adjusted break, the burner starts to operate again.
3. Curing Period Adjusting:
   The curing period beginning from 200°C is adjusted; and when the adjusted curing period is completed, an automatic horn will alert.
4. Adjusting of Exhaust Fan and Horn Period:
   When the adjusted curing period is completed, the exhaust fan begins to operate automatically and the horn alerts. The exhaust fan and the horn period can be adjusted through the thermostat. If needed, the exhaust fan can be operated manually while the oven is operating.

Oven Exhaust Issues

Gas convection cure ovens and some dry-off ovens are exhausted to remove raw fuel, byproducts of combustion, and any emissions from the coating materials. The coating materials may include compounds that are emitted by design, as well as decomposition byproducts from fallen powder or parts.

By necessity, ovens designed to cure conventional solvent-borne coatings must have much higher exhaust rates to remove hazardous solvents from the oven and work atmosphere. The removal of combustion byproducts is critically important to prevent the yellowing or darkening of light colors. General guidelines for powder cure ovens are:

• Three air turnovers per hour for non-appearance parts.
• Four to Six air turnovers per hour for dark colors.
• Six to Eight air turnovers per hour for clear coatings.
• Eight to Twelve air turnovers per hour for light colors and appearance parts.
  Certain situations may require higher exhaust rates:
• Curing solvent-borne or Ecoat in the same oven with powder. The
  byproducts of these can interfere with powder cure or produce yellowing in light colors.
• Curing multiple powder chemistries in the same oven environment can
  produce gloss reduction and even wrinkling in a smooth coating.
• Combination cure and dry-off ovens. High exhaust rates required to remove water vapor.
• Contaminated makeup air (plant air) is used rather than fresh outside air. The number of air turns in an oven is the rate at which fresh air replaces the initial air volume by the oven blower. The exhaust requirements can vary greatly with oven design.

Indirect burners represent far less of a problem with combustion gases than direct-fired burners. The air turns for direct-fired ovens should be higher. If the oven is exhausted over a period of time contaminants such as nitrous oxides and sulfur dioxide may build up to produce a condition known as a fouled oven.

In these cases, some coaters place buckets of liquid Ammonium Hydroxide or solid Ammonium Salts at the oven exit and entrance at shutdown to assist in neutralizing these acidic materials. Additionally, cleaning and servicing the burners may be necessary. The formula for determining Oven turns is:

Oven Turns = Make-up air exchange Rate/Oven Volume

Oven Residue

Oven residue is the buildup of grease, food particles, and other debris that can accumulate inside an oven over time. If left unchecked, oven residue can become a fire hazard and can also make it difficult to clean the oven effectively.

Causes of Oven Residue

There are several causes of oven residue, including:

• Spills and splatters: Cooking inevitably leads to spills and splatters, which can harden and become difficult to remove if not cleaned up promptly.
• Overheating: If food is overheated, it can break down and release grease and other substances that can stick to the oven walls and floor.
• Not cleaning the oven regularly: If the oven is not cleaned regularly, grease, food particles, and other debris will have a chance to build up and become more difficult to remove.

How to Prevent Oven Residue

There are several things you can do to prevent oven residue from building up:

• Clean up spills and splatters promptly: If you spill something in the oven, clean it up as soon as possible. This will prevent the spill from hardening and becoming more difficult to remove.
• Avoid overheating food: If you are cooking something in the oven, make sure to avoid overheating it. This will help to prevent grease and other substances from being released.
• Clean the oven regularly: You should clean the oven regularly to prevent grease, food particles, and other debris from building up. A good rule of thumb is to clean the oven every two weeks.

How to Clean Oven Residue

If you do have oven residue, there are several ways to clean it. Here are a few tips:

• Use a baking soda paste: Baking soda is a natural abrasive that can help to remove grease and food particles from the oven. Make a paste by mixing baking soda with water, and then apply it to the affected area. Let the paste sit for several hours, or overnight, and then scrub it off with a sponge or brush.
• Use a commercial oven cleaner: There are many commercial oven cleaners available that can help to remove oven residue. Be sure to follow the instructions on the cleaner carefully, and wear gloves and a mask when using it.
• Use a self-cleaning oven: If your oven has a self-cleaning function, you can use it to clean the oven. However, be sure to read the instructions carefully before using the self-cleaning function, as it can damage the oven if it is not used properly.

Conclusion

Oven residue is a common problem, but it can be prevented and cleaned. By following the tips above, you can keep your oven clean and prevent fire hazards.

Many powder coating ovens have an oven fuzz that builds up in and around the cool zones such as the vestibule at the oven opening and around the exhaust fan. This material is generally made up of:

• Low molecular weight resins
• Flattening agents
• Blocking agents
• Degassing agents
• Decomposition products from the resin
  The cause of build-up is generally caused by poor oven design or poor maintenance. This oven residue should be cleaned out by vacuuming or washing with a power spray washer.
  Other factors which may contribute are:
• The frequent line stops with a full load in the oven.
• Excessive oven temperatures
• Uneven heat in the oven results in hot and cool zones. This can result
  from baffling, the placement of a cooling tunnel or poor insulation on the exterior facing walls.

Hazards associated with these residues are:

• Flammability
• Inhalation by workers
• Contamination of the finished part.
  Note, even though not all residues represent fire hazards they should be treated as such.

Warning related to the operation of the drying oven

• If the oven is going to be operated for the first time, the rotation directions of all motors (fan, Burner…etc.) must be checked one by one, If they are wrong, they must be corrected by an authorized electrician. While checking the motor’s direction, it shall not operate for a long time, it must be checked by operating it for one or two seconds then stopping it, and so on.
• Especially the chimney of the heating unit (burner) must absolutely be produced by its manufacturer and must have the ability for sufficient pulling. Otherwise, the burner’s adjustments won’t be right; moreover, the burned poisonous gases will spread to the factory’s environment.
• The fuel (Natural gas, LPG…etc.) which enters the burner must be coming from a line with appropriate pressure, flow, and cross-section.
• Maintenance and cleaning of the oven must be done at the proper time. An unauthorized and uninformed person shouldn’t interfere with or use the oven.
• In starting each curing operation “RESET” button should be pressed. Otherwise, the adjustments that have been made in the thermostat will not be active, and the curing process will not be done.
• Close circulation fans while material enters the oven. In this case, the paints that exist on the material won’t spill while the material enters the oven, heat loss will decrease, also no excessive hot air will come over the operator. Open the circulation fans again after closing the doors.
• Cured parts and hanger apparatuses in the discharge region should absolutely be taken down before operating the conveyor.
• During operating, the curing period of the parts inside the oven is bound. At the end of the curing period, the parts inside the oven should absolutely bring out. Even if there are not enough painted (that will cure) parts in the loading region the doors should open and the parts inside should bring out, and the parts in the loading region should enter inside the oven.

The Periodic Maintenance of the Powder Drying Oven

Periodic maintenance is crucial for ensuring the optimal performance and longevity of a powder drying oven. Regular inspection and upkeep help to identify and address potential issues early on, preventing costly repairs and downtime.

Importance of Periodic Maintenance

1. Maintaining Drying Efficiency: Regular maintenance ensures that the oven components, such as heating elements, fans, and airflow ducts, are functioning properly, promoting efficient heat distribution and consistent drying results.
2. Preventing Equipment Failure: Timely maintenance helps to identify and resolve minor issues before they escalate into major breakdowns, minimizing downtime and costly repairs.
3. Extending Oven Lifespan: Proper maintenance practices help to prolong the lifespan of the oven, reducing the need for frequent replacements and associated expenses.
4. Enhancing Safety: Regular maintenance ensures that the oven is operating safely, preventing fire hazards, electrical issues, and potential injuries to users.
5. Optimizing Energy Consumption: Well-maintained ovens operate more efficiently, consuming less energy and reducing overall operating costs.

Recommended Maintenance Schedule

1. Daily Inspections: Perform daily visual inspections to check for signs of damage, loose components, or unusual operation.
2. Weekly Cleaning: Clean the oven interior, exterior, and air filters to remove dust, debris, and accumulated powder residue.
3. Monthly Inspections: Conduct more thorough inspections, checking the functionality of heating elements, fans, airflow patterns, and temperature controls.
4. Semi-annual Maintenance: Engage a qualified technician to perform a comprehensive maintenance check, including lubrication of moving parts, calibration of controls, and replacement of worn-out components.
5. Annual Deep Cleaning: Perform a deep cleaning, including disassembly of major components, thorough cleaning of internal mechanisms, and replacement of filters and gaskets.

Additional Maintenance Tips

1. Follow Manufacturer’s Instructions: Refer to the manufacturer’s manual for specific maintenance guidelines and recommended intervals.
2. Use Proper Cleaning Agents: Use only cleaning agents recommended by the manufacturer to avoid damaging the oven’s components.
3. Maintain Proper Ventilation: Ensure the oven is adequately ventilated to prevent the buildup of fumes and moisture.
4. Store Properly: When not in use, store the oven in a clean, dry environment to prevent dust accumulation and damage.
5. Promptly Address Issues: Do not ignore any signs of malfunction or damage. Address issues promptly to prevent further problems.
6. Regular Training: Provide regular training to oven operators on proper usage, maintenance procedures, and safety precautions.
7. Keep Maintenance Records: Maintain a log of maintenance activities, including dates, tasks performed, and any observations.

By following these maintenance recommendations, you can ensure that your powder drying oven operates efficiently, safely, and with a long lifespan, maximizing its value and minimizing disruptions to your operations.

Guarantee of the Drying Oven

•Drying Oven is guaranteed for 3 (two) years against manufacturing and material faults (Except Electrical Parts). The parts replaced within the scope of the guarantee are free of charge.
•Damages resulting from faulty usage and/or intervention of unauthorized people are outside the scope of the guarantee.