Infrared boosters optimize your production plant

Production bottlenecks often occur as a result of tougher production demands, where the existing drying system can no longer keep pace. This can often be solved by an infrared booster section, which is positioned in front of the existing drying system.

Infrared boosters

The booster section rapidly brings the product up to temperature allowing line speeds to be increased accordingly. For some products this can equate to savings of up to 50% of the time required to dry or cure the coating.

Next to the classic booster - an infrared module placed in front of another heating module - a booster can also be placed after the existing oven or in between.

Your advantages using infrared boosters:

  • Saving time by faster heating
  • Saving space through shorter drying distances
  • Saving energy through fast reaction times

There are electric and gas-catalytic infrared boosters. The specific framework conditions of product and process determine the selection. In practice, different combinations are used for boosters. For example, infrared modules in front of a hot air oven or an electric infrared booster together with a gas-catalytic infrared oven.

See for yourself how infrared boosters can optimize your existing production plant!
Here are some application examples:

IR booster speeds up manufacture of metal housings

So far, metal compressors for small cooler units have been cured with long wave infrared emitters. The emitters were replaced with medium wave twin tube emitters from Heraeus. In addition, a so-called infrared booster with high-power, short wave emitters was fitted in the line in front of the oven. The booster is used to bring the product quickly to the correct temperature.

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QRC IR emitters improve quality of motor vehicle suspension springs

Thanks to an infrared system from Heraeus, Ahle Federn was able to achieve a higher quality in the coating of vehicle suspension springs. Infrared systems save space, and the new IR oven could be installed directly in front of the powder coating plant, with little change to the existing production layout. The IR oven heats the springs before the powder coating, which is then cured by a hot air oven.

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Pre-Gel IR System for trailer manufacture

In order to achieve the required quality of finish, the speed of the Gatormade Trailers production line had to be reduced almost to a standstill. Only then could it be ensured that the powder flowed correctly and gave a consistent gloss. Because this slowdown was not acceptable, the system had to be brought back to its original speed. Subsequently, a Pre-Gel gas-catalytic IR oven from Heraeus-Vulcan Catalytic was installed in front of the actual convection oven. This configuration helps to raise the temperature of the powder extremely quickly to the point where it starts to gel.

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IR emitters improve flexibility and controllability in flooring manufacture

Infrared systems from Heraeus Noblelight are used at various points in the production of vinyl flooring, allowing manufacturing controllability and improving the production flexibility of the line. The basic manufacturing process for floors consists of building up thicknesses of PVC paste on a PVC backing layer, which features a fiber glass internal matting. The application of heat is an important part of the process, both to dry the backing layer and to ensure effective curing of the applied PVC pastes. Effective curing is provided by medium-wave infrared emitters from Heraeus Noblelight.

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IR emitters for the powder coating of MDF

A Heraeus Noblelight infrared booster helps Sauter GmbH powder-coat MDF boards. Boards like this are widely used for tables, cabinets and office furniture. However, the powder coating of these boards posed a challenge to the company as wood fibres are hardly electronically conductive and are also sensitive to heat. The previously used powder coating oven soon reached its capacity limit, which is why they opted for an infrared booster from Heraeus Noblelight. The booster was installed directly behind the coating station where the powder is preheated to 140°C - 150°C and gelled within a few seconds.

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Short-wave IR emitters for powder coating of engine housings

Demag Cranes and Components manufactures high value engines, which feature a high value housing with a top class coating. In the end, electric infrared emitters were chosen as the heating source, because infrared radiation is readily absorbed by powder, so that the powder heats up very quickly. Powder is gelled significantly better by infrared than it is in a convection oven. Fast gelling improves the coating quality and permits higher line speeds. Today, the engine housings are rotated as they travel through the plant and are electrostatically coated in a fully automatic process using an orbital conveyor. The powder is first heated melted in the heating zone and then cured in a holding zone.

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Your application is not listed? Infrared can do so much more!
Contact us and find out more!

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