Kai K. O. Bär, adphos Thermal Processing GmbH F. Bielefeld, Technical Consultant, Schwerte NEW SUPPLY CHAINS AND NEW OPPORTUNITIES FOR COIL COATERS TO GAIN MARKET SHARE OF POST-PAINTED COMPLETE GOODS NIR is a trademark of adphos. adphos owns more than 200 patents- or patent applications on the NIR-technology 18 th Galvanizing & Coil Coating Conference, September 10-11, 2013
Introduction Coil coated steel production up to 1.24 Mrd m² 2008 before the crises this is approx 5.6 Mio t/a current coil coating on the level of before the crises 95 % is based on galvanized steel But only 25 % of galvanized steel is coil coated 2
Galvanized coils are coated as.. Car body 35 % (= 7.8 Mio t/a) Post paintings 40 % (= 9 Mio t/a) Substitutionsdirection Coil Coating 25 % (= 5.8 Mio t/a) 3
Today s Situation Coil coating or post-painting? large batches* coil coating costs 0.79 /m² * > 20 t teletronics electronics Lightning appliances office equipment, furniture signs buildings, roof- and wallelements, doors, solar roofs automotive parts small batches post-painting costs 2.50-5.00 /m² Batch size decides! 4
Vision Small size coil coating facility for small batches ( 0.2 t) start-up production of new products and customized solutions decentralised and just in time production 5
Small size / compact CCL?? 6
Conventional CCL 7
Compact Line Downsized Conventional CCL 8
NO 9
MiCConD Compact Coil Coating Also small batches (200 kg and above) can be coil coated The coils can be pre-treated, primed and finish coated The quality and environmental standards are the same as for CCL s The process is based on a start-stop principle with the instantaneous NIR-drying/curing technology The production costs of coated coils are at the level of large CCL s The critical mass is below ¼ of CCL s Significant lower investment costs From order to start up production in 12 month 10
Principal MiCConD - Process 11
MiCConD Configuration 1 (2 coat, 2 sides) (1) 12
MiCConD Configuration 1 (2 coat, 2 sides) (2) Technical Data: Substrate: Width: Thickness: Ref. coil (St): Ref. throughput (St): Max. solvent load: Total connected power: Max. coil weight: Al, St 300 mm 1,250 mm 0.15 mm 1.2 mm 0.6 mm x 1,250 mm at 20 m/min 7 t/hr 90 kg/hr 1,400 kva 25 t 13
Major Application Fields (2) Today s Coil Coater Service Centers - Just in time on order delivery (esp. color, coil geometries, volume) esp. integration in slitting and/or cut to length lines 14
MiCConD Configuration 2 (2 side coating) (1) 15
MiCConD Configuration 2 (2 side coating) (2) Technical Data: Substrate: Width: Thickness: Ref. coil (St): Al, St 300 mm 1,250 mm 0.15 mm 1.2 mm Option A) 0.6 mm x 1,250 mm at 30 m/min Option B) 0.6 mm x 1,250 mm at 20 m/min Ref. throughput (St): Option A) 10.6 t/hr Option B) 7.0 t/hr Max. solvent load: Option A) 80 kg/hr Option B) 50 kg/hr Total connected power: Max. coil weight: Option A) 900 kva 10 t, 15 t, 20 t Option B) 600 kva 16
MiCConD Configuration 3 Slitting Line (1 side) (1) 17
MiCConD Configuration 3 Slitting Line (1 side) (2) Technical Data: Substrate: Width: Thickness: Ref. coil (St): Ref. throughput (St): Max. solvent load: Total connected power: Max. coil weight: Al, St up to 1,500 mm 0.1 mm 1.5 mm 1.2 mm x 1,500 mm at 30 m/min 25.5 t/hr 70 kg/hr 2,100 kva 25 t 18
Major Application Fields (3) Vertical Coil Processing Vertical coil processing Integration in roll forming Integration in roll to sheet process lines esp. replacement of today s component coating applications 19
Schematically Layout of MiCConD Rollforming Process 20
MiCConD Configuration 4 Powder Coating (1 side) (1) 21
MiCConD Configuration 4 Powder Coating (1 side) (2) Technical Data: Substrate: Width: Thickness: Ref. coil (St): Ref. throughput (St): Max. powder: Total connected power: Max. coil weight: Al, St 500 mm 1,650 mm 0.1 mm 1.5 mm 0.6 mm x 1,650 mm at 20 m/min 9.3 t/hr 130 kg/hr ( 50 µm) 1,150 kva 10 t, 15 t, 20 t 22
Major Application Fields (4) Today s Coil Coater Emerging markets for coil coating Coating manufacturer or further coating process developments Sampling production for new products Process/feasibility verification for new process/measurement components 23
Pilot Line for Coating Manufacturer (1 side coating) (1) 24
Pilot Line for Coating Manufacturer (1 side coating) (2) Technical Data: Substrate: Width: Thickness: Ref. coil (St): Ref. throughput (St): Max. solvent load (1 side): Total connected power: Max. coil weight: Al, St up to 300 mm 0.1 mm 1.25 mm 0.5 mm x 300 mm at 15 m/min 1 t/hr 7 kg/hr 140 kva 200 kg 25
Full Performance MiCConD Production of 200 kg to 20 t Batches 20 m Including VOC-treatment Investment depending on output 3-5 Mio. 26
(Recommended) Pre Products for MiCConD Process Pretreated coils in CGL Twice operation of primer/finish applications in MiCConD Preprimed coils treatment primer in post-treatment section in CGL Finish coating application in MiCConD Clear or cleaned coil substrate as required (galv, stainless steel, aluminum, ) Integration of chemcoating + twice operation of primer/finish in MiCConD 27
Cost Study: Two Coat MiCConD Pretreatment primer both sides (each 5 µm) Finish coating 20 µm Substrate: galvanized steel Galvanized steel Org. coated steel Dryer Finish coating Cooling 28
Cost Study: Two Coat MiCConD (2) *including coil margins and repairs 29
Quelle: M. Obst, Lackierereien planen und optimieren, Hannover, 2002; A. Ritterbach, Rippert Anlagenbau, 8/2011; F. Bielefeld, J. Sander, The profitable choice: From small-batch post-painting to Compact Coil Coating, Berlin, 10/2011 30
Assumptions/Boundary Conditions: Production 2,750 t/month 583,000 m² ; 8 t/h; two shifts Dimensions: 0.6 x 1,250 mm (0.35-1.25 x 700-1.500 mm) Color and coil changes: 320 per month Speed: up to 30 m/min, but calculated with 20 m/min Handling effort: 15 min Coil Margins: typical 3 %; but calculated with 4 % Personnel costs: 42 /h Investment: 4.1 Mio incl. VOC (no building) Space: 125 m²; 4 /m² calculated rental fee Depreciation: 10 years Interest Rate: current 5 %; but calculated with 10 % Unknowns and uncertainties are well reflected in above 31
Costs per Production.even at 1,000 t/month already MiCConD costs below 1 /m² 32
Special Benefits of MiCConD (1) Low preparation effort (max. 15 30 min) Min. scrap ( 5 m coil loss) Smallest space requirements ( 5 m complete coating process; 15 m complete stand-alone solution) Dynamic coating operation from start to stop the line Extreme flexible process/product as well as production scenarios No manual process operation necessary (fully atomized and self controlled) manual coil feed in/out manual coater preparation manual coater cleaning / color change High process efficiency and state of the arte and green technology 33
Special Benefits of MiCConD (2) Low maintenance / service requirements Clean ambient conditions and low infrastructural requirements (electricity, air, eventual water, gas for VOC) Low investment costs < 12 month from order to production Pre-acceptance at adphos with coil coating operation Installation at customer within max. 2 weeks later 34
Summary MiCConD-process provides additional and attractive business esp. for service centers for customized and/or decentralised small batches and just in time coil coating production MiCConD-process provides additional access to the 10 Million t/a post-painted market which can not be reached with todays CCL-capacities/capabilities 35
Cost Saving by MiCConD-Process 36
Costs MiCConD based solutions provide Break even at 2.500 5.000 t/a Proven! 37
Conclusion MiCConD is not a competition to existing standard CCL`s MiCConD is not a product but a modular, flexible concept to allow new coil coating processes! 38
MiCConD Micro Color Coating on Demand Coil coating in a size of a living room Not only a vision! 39