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THE PROFESSIONAL FOR
BIOLOGICAL AIR PURIFICATION SYSTEMS

To protect the environment, the pollutants from gases and vapours produced during painting must be cleaned before exhaust air is released into the atmosphere. Since thermal cleaning systems are neither emission-free nor energy-saving, biological exhaust air purification using microorganisms is the ideal solution for removing pollutants from high exhaust air flows in a cost-efficient and environmentally friendly manner.

Advantages of AFOTEK's biological exhaust air purification systems

  • Environmentally friendly process to minimise pollutants (biofilter)

  • Low space requirement (optimal use of operating space)

  • The system can also be placed outside the production hall

  • Individually configurable (modular principle)

  • Alignment with customer needs (flexible adjustment of system capacity, system size and volume flows)

  • Operation and regulation of pumps, fans, sensors and optional heating

  • Low maintenance effort thanks to fully automated control technology (control cycles and maintenance times are significantly reduced)

  • Situational equipping of heat recovery systems possible

  • Biologische Abluftreinigungsanlage

  • Abluftstroeme Biologisch Reinigen

  • Gesamtansicht

    Gesamtansicht

  • Rotationswärmeaustauscher

    Rotationswärmeaustauscher

  • Vorwäscher

    Vorwäscher

  • Components

    Two cylindrical reactor towers, which are filled with a special, structured carrier material, are a key component of the biological exhaust air purification system. These structured packings are exposed to a suspension of water, microorganisms and chemicals, resulting in the formation of a biofilm

  • Operating principle

    The active principle of biological exhaust air purification is based on the use of aerobic microorganisms, which convert the incoming air pollutants into harmless end products, such as carbon dioxide and water. The active principle is based on the one hand on the flow of structured packings and the conversion of dissolved pollutants in a storage tank.

  • Technical design

    Biological exhaust air purification is designed specifically for the individual application. A system concept is developed in collaboration with the customer, which can be optimally integrated into existing system concepts.

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SPECIALISATIONS
AT A GLANCE

Automation and digital solutions

Ultra-modern and intelligent system solutions ensure that painting system operators can work profitably. In addition to transparent processes and digital documentation, robotic painting systems and handling robots ensure cutting-edge system technology in accordance with the Industry 4.0 standard. Interfaces to upstream and downstream ERP and/or MES systems round off the innovative control concept.

  • Robotics
  • Dashboard
  • Real-time simulation in 3D/material flow
  • Automation technology

    (MES, ERP solutions etc.)

  • Lackieranlagen

  • Pulverbeschichtungsanlagen

  • KTL Tauchlackieranlagen

  • Vorbehandlungsanlagen

  • Trocknungsanlagen

  • AFOTEK Shuttle Foerdertechnik (ASF)

  • Biologische Abluftreinigungsanlagen

  • Digitale Lösungen

  • Icon Telefon

    Telefon

    +49 6621 5076 0

  • Icon E-Mail

    E-Mail

    This email address is being protected from spambots. You need JavaScript enabled to view it.

  • Icon Uhr

    Montag-Freitag

    08:00–16:00 Uhr

  • Last updated on .

AFOTEK SHUTTLE CONVEYOR SYSTEM
(ASF) – CONVEYOR TECHNOLOGY AT THE HIGHEST LEVEL

AFOTEK Shuttle Conveyor System (ASF)
Conveyor technology at the highest level

The AFOTEK Shuttle Conveyor System (ASF) is an innovative transport system with maximum flexibility. It features a modular structure, so can be expanded as required and individually adapted to your needs. In addition, the conveyor system stands out from conventional solutions thanks to its extremely flexible drive concept. With the AFOTEK Shuttle Conveyor System (ASF), the transport of product carriers is not dependent on a chain; instead, each product carrier can be controlled separately and individually – a new dimension in product carrier logistics.

Advantages of the AFOTEK Shuttle Conveyor System

  • Quick and easy installation of the system

  • Variable and reversible in terms of speeds, directions of movement and stops

  • Any retrieval options through buffers (e.g. sorting function or use as a “dead station”)

  • Individual control and regulation of product carriers

  • Flexible process speeds within one system

  • Space-saving structure – can also be implemented on several levels

  • Expandable conveyor system

Flyer PDF

  • 211026 AFOTEK Interroll ASF Fotografie DSC 00003 EDIT Rot

  • AFOTEK Shuttle Firdertechnik ASF

  • Querverschub AFOTEK Shuttle Firdertechnik ASF

  • Individual and flexible shuttle conveyor technology

    With conventional conveyor technology solutions, all of the goods are transported using a conveyor chain, which means that all components move through the system at the same conveyor speed. All workpieces go through the pretreatment, painting and drying process with identical cycle times.

    With the AFOTEK Shuttle Conveyor System (ASF), however, each transport unit has its own drive unit with individual control. This means that each product carrier can be flexibly controlled as required. On the one hand, this enables variable process speeds within the system, and on the other hand, reverse travel can also be implemented within a process.

    The flexible drive concept allows you to drive through coating booths at low speeds and to pick up speed and speed on open transport routes. With AFOTEK’s conveyor technology, processing cycle times can be designed independently, which leads to significantly higher efficiency, lower process costs and faster throughput times.

    The individual shuttles can bridge up to 250 mm without transport rails, which means that the conveyor rail, e.g. in fire gates or other fire compartments, can be interrupted without restricting transport.

  • Conveyor technology with a modular structure: flexibility with a system

    The flexibility of the AFOTEK Shuttle Conveyor System (ASF) is based on a fully modular rail system that can be used to implement a wide variety of system layouts.

    The heart of the ASF are the transport rails made of anodized aluminium profiles with internal rollers. Transport shuttles are used to carry products and run on the rails with little lubrication and little maintenance. Depending on the size of the part, the transport shuttles are custom-made, one to eight metres in length as desired.

    The flexibility of the conveyor system goes so far that transport rails can be arranged parallel in some areas of the system, for example in transverse displacement magazines, buffers or ovens. This makes it possible to move a large number of product carriers at the same time in a very small space. Cross-transport is also possible in this constellation and ensures a closed transport cycle within the system.

    Thanks to the highly flexible, modular structure, layouts of almost any size can be constructed. AFOTEK's conveyor technology adapts perfectly to available spatial constraints and customer production processes. In confined spaces, compact solutions that extend over several floors are also possible.

    The AFOTEK Shuttle Conveyor System can be expanded and modified cost-effectively at any time, as the desired modules, e.g. buffers or transverse displacement magazines, can be easily integrated into the existing system. Overtaking routes can also be retrofitted without much effort.

AFOTEK SHUTTLE CONVEYOR SYSTEM (ASF) REFERENCES

  • Bonda Color Design

  • Dpi Trdesign

  • Indula

  • Kaercher

  • VARISOL

SPECIALISATIONS
AT A GLANCE

Automation and digital solutions

Ultra-modern and intelligent system solutions ensure that painting system operators can work profitably. In addition to transparent processes and digital documentation, robotic painting systems and handling robots ensure cutting-edge system technology in accordance with the Industry 4.0 standard. Interfaces to upstream and downstream ERP and/or MES systems round off the innovative control concept.

  • Robotics
  • Dashboard
  • Real-time simulation in 3D/material flow
  • Automation technology

    (MES, ERP solutions etc.)

  • PAINTING SYSTEMS

  • POWDER COATING SYSTEMS

  • DIP COATING SYSTEMS (CDC)

  • PRETREATMENT SYSTEMS

  • DRYING SYSTEMS

  • AFOTEK SHUTTLE CONVEYOR SYSTEM (ASF)

  • BIOLOGICAL EXHAUST AIR PURIFICATION SYSTEMS

  • DIGITAL SOLUTIONS

  • Icon Telefon

    Telefon

    +49 6621 5076 0

  • Icon E-Mail

    E-Mail

    This email address is being protected from spambots. You need JavaScript enabled to view it.

  • Icon Uhr

    Montag-Freitag

    08:00–16:00 Uhr

  • Last updated on .

THE PROFESSIONAL FOR
DRYING SYSTEMS

Drying Systems

Proper and professional drying is the final process step in surface coating and is fundamentally important for the quality of the coating. Whether steel, aluminium or plastic – AFOTEK relies on highly effective processes for drying the workpieces and offers individual solutions depending on the coating process (powder coating or wet paint coating) and the process step. These include powder baking ovens, adhesive water dryers, paint dryers, refrigeration dryers, infrared dryers, chamber dryers and core dryers.

Drying systems can generally be delivered individually or integrated as a downstream drying process within the painting system or powder coating system.

Many components of our drying systems are manufactured and pre-assembled at AFOTEK, so that the powder baking ovens, paint dryers and adhesive water dryers as well as the associated units are delivered in modules of the largest possible size This significantly reduces on-site assembly time.

When designing the system, AFOTEK relies on energy-efficient system control and heat recovery systems using heat pumps. The software development and visualisation is carried out by in-house PLC programmers. If desired, it is possible to connect an ERP or MES system that transfers the production data directly to the pretreatment line of the painting system, as well as the integration of product tracking or data tracking including history.

Advantages of drying systems

  • Use of waste heat possible through intelligent and energy-efficient system control.

  • Optimised use of energy through heat recovery measures.

  • Energy savings through high-quality insulation of the dryer panels.

  • The majority of the components are manufactured in our factory in Bad Hersfeld (units, dryer plates, etc.)

  • Delivery of prefabricated modules significantly shortens assembly times.

  • Lacktrockner

  • Pulvereinbrennofen Mit AFOTEK Shuttle Firdertechnik

  • Haftwassertrockner Transformed

  • Haftwassertrockner 2

  • Digitaler Anlagenzwilling Pulvereinbrennofen

  • Powder baking oven

    Once the powder has been applied during the powder coating process, the workpieces are placed in the powder baking oven. Baking temperatures vary between 180 °C and 240 °C depending on the type of powder. Whenever possible, the dryers are pre-assembled so that the finished elements or components arrive at the customer fully assembled.

  • Adhesive water dryer

    After leaving the pretreatment system, the surfaces of the workpieces must be dried and freed from adhering water particles. This is done in so-called adhesive water dryers. The special design of the adhesive water dryer, together with the temperature-controlled circulating air, ensures a surface that is perfectly prepared for subsequent painting.

  • Paint dryer

    Depending on which paint system was previously used, the paint is dried at different temperatures and residence times. AFOTEK uses recirculation processes and high-quality dryer insulation to keep energy costs as low as possible. In addition, our focus is on reducing the size of the furnace inlet and outlet openings to minimise energy loss.

  • Chamber dryer/core dryer

    For smaller quantities or when using trolleys, chamber dryers or trolley dryers are used. In this case, the dryer usually consists of a chamber with a loading and unloading door. The workpieces or tray trolleys are placed in the dryer and remain there for a previously defined period. After drying is complete, the drying chamber is emptied and is available for restocking.

  • Infrared and UV dryers

    Infrared and UV dryers represent an alternative to conventional drying processes, such as circulating air drying. In this case, drying takes place using infrared or UV radiation. However, this requires use of the appropriate painting systems, since, for example, special UV-curing varnishes must be used for UV drying.

  • Refrigeration dryer

    Refrigeration drying uses temperatures between 30 °C and 60 °C. This low-temperature process uses the energy potential of moist air, which is circulated in a closed circuit. In order to achieve the desired extremely dry climate, moist air in the bypass is continuously dehumidified. Refrigeration drying can be used in both continuous and chamber dryers.

DRYING SYSTEM REFERENCES

  • AGCO Fendt

  • Collini Gmbh

  • Erfal

  • Giga Coating

  • Stadtmission Chemnitz

  • Welco

SPECIALISATIONS
AT A GLANCE

Automation and digital solutions

Ultra-modern and intelligent system solutions ensure that painting system operators can work profitably. In addition to transparent processes and digital documentation, robotic painting systems and handling robots ensure cutting-edge system technology in accordance with the Industry 4.0 standard. Interfaces to upstream and downstream ERP and/or MES systems round off the innovative control concept.

  • Robotics
  • Dashboard
  • Real-time simulation in 3D/material flow
  • Automation technology

    (MES, ERP solutions etc.)

  • PAINTING SYSTEMS

  • POWDER COATING SYSTEMS

  • DIP COATING SYSTEMS (CDC)

  • PRETREATMENT SYSTEMS

  • DRYING SYSTEMS

  • AFOTEK SHUTTLE CONVEYOR SYSTEM (ASF)

  • BIOLOGICAL EXHAUST AIR PURIFICATION SYSTEMS

  • DIGITAL SOLUTIONS

  • Icon Telefon

    Telefon

    +49 6621 5076 0

  • Icon E-Mail

    E-Mail

    This email address is being protected from spambots. You need JavaScript enabled to view it.

  • Icon Uhr

    Montag-Freitag

    08:00–16:00 Uhr

  • Last updated on .

THE PROFESSIONAL FOR
PRETREATMENT SYSTEMS

Pretreatment systems

Proper and professional pretreatment of the workpieces is the cornerstone of high-quality coating. From steel to aluminium to plastics, AFOTEK relies on highly effective processes for cleaning, degreasing, phosphating, pickling and conversion treatment. In pretreatment systems, workpieces are first degreased and cleaned. If necessary, a corrosion protection layer or conversion layer is then applied. Depending on the component and the necessary pretreatment process, the components subsequently pass through rinsing zones and, if necessary, are passivated, phosphated or neutralised.

In addition to the classic pretreatment systems such as continuous spray systems, chamber spray systems and immersion cleaning systems, the AFOTEK product portfolio also includes ionisation systems, flame treatment systems, CO2 cleaning systems and snow blasting systems. The pretreatment system can be installed as a standalone system or as an upstream cleaning process within painting systems or powder coating systems.

The pretreatment systems are manufactured and completely pre-assembled at AFOTEK, so that continuous pretreatment systems, chamber pretreatment systems or immersion pretreatment systems are delivered in modules of the largest possible size. This significantly reduces assembly time when installing on site.

When designing the system, we focus on intelligent and energy-efficient control. The software development and visualization is carried out completely in-house by AFOTEK PLC programmers. As with our other systems, it is possible to connect to the customer's ERP/MES system to transfer production data, as well as product and data tracking including history.

Advantages of pretreatment systems

  • Intelligent and energy-efficient system control

  • Optimised use of energy through heat recovery measures

  • Highest processing quality through in-house production

  • Delivery of prefabricated modules significantly shortens assembly times

  • Durchlaufvorbehandlungsanlage

  • Taktvorbehandlungsanlage

  • Tauchlackieranlagen

  • Continuous pretreatment systems

    Continuous pretreatment systems -also known as continuous spray systems- are usually used in wet chemical processes for medium and high throughput. During wet chemical pretreatment, metal surfaces are cleaned using chemicals and heat, with water acting as a carrier material. The pretreatment and cleaning of the workpieces is carried out regularly in several coordinated cleaning steps, between which rinsing processes take place.

    The structure of the continuous pretreatment systems depends on the workpiece shape and size, part throughput and the material to be processed. As part of the system planning, AFOTEK, together with the chemical supplier, develops a pretreatment concept tailored to the customer's needs for cleaning parts before the surface is coated in the painting system.

    Parts can be transported within the painting system or powder coating system using conventional conveyor technologies, such as a power-and-free conveyor, a circular conveyor system or the AFOTEK Shuttle Conveyor System (ASF).

    Continuous spray systems are environmentally friendly, energy efficient and investment-friendly and can be implemented for a wide range of component sizes.

  • Chamber spray systems

    Chamber pretreatment systems or chamber spraying systems are primarily used in the metal industry and are integrated into powder coating systems as an upstream cleaning process. A liquid cleaning medium is applied to the workpieces to be cleaned through adjustable nozzles, which dissolves contaminants and rinses them from the workpiece.

    In chamber pretreatment systems, several cleaning steps take place in one chamber. To do this, the workpieces enter one or more chambers – depending on the throughput and the required treatment steps. As part of the project planning, AFOTEK equips the spray system so that the workpieces are optimally flooded on all sides. This is made possible by an offset nozzle system. The additional mechanical effect of the spraying process means that significantly shorter treatment times can be achieved at lower bath temperatures compared to immersion pretreatment systems. In addition, the system footprint is smaller compared to immersion pretreatment systems while process control is simpler.

  • Immersion cleaning systems

    Workpieces with surfaces that are difficult to access are ideally treated in immersion cleaning systems. These offer the security that not only the external
    surfaces but also all cavities and edges are reached. This type of pretreatment is particularly recommended for complex geometries where a spray system cannot reach the entire surface. Immersion cleaning systems are often used in vehicle construction as well as in agriculture and forestry as an upstream cleaning process in CDC systems.

    AFOTEK plans and configures the entire system based on the products being cleaned and customer-specific requirements and, together with the chemical supplier, develops the best possible concept with regard to the number and duration of the process steps. The various dipping pools are usually arranged in a row or in a horseshoe shape. The size of the dipping pretreatment depends on both the workpiece size and the required treatment steps. An integrated conveyor system, for example a cycle lifter system, rounds off the automated AFOTEK immersion pretreatment process. After the pretreatment process, the workpieces can be transferred from the cycle lifter to a power-and-free system or another type of conveyor system.

    In addition to lower energy consumption compared to conventional spray pretreatment systems, dip pretreatment is also characterised by high-quality corrosion protection of steel and aluminium components.

PRETREATMENT SYSTEM REFERENCES

  • AGCO Fendt

  • Erfal

  • Giga Coating

  • Reku Color Gmb H

  • Welco

Specialisations
at a glance

Automation and digital solutions

Ultra-modern and intelligent system solutions ensure that painting system operators can work profitably. In addition to transparent processes and digital documentation, robotic painting systems and handling robots ensure cutting-edge system technology in accordance with the Industry 4.0 standard. Interfaces to upstream and downstream ERP and/or MES systems round off the innovative control concept.

  • Robotics
  • Dashboard
  • Real-time simulation in 3D/material flow
  • Automation technology

    (MES, ERP solutions etc.)

  • PAINTING SYSTEMS

  • POWDER COATING SYSTEMS

  • DIP COATING SYSTEMS (CDC)

  • PRETREATMENT SYSTEMS

  • DRYING SYSTEMS

  • AFOTEK SHUTTLE CONVEYOR SYSTEM (ASF)

  • BIOLOGICAL EXHAUST AIR PURIFICATION SYSTEMS

  • DIGITAL SOLUTIONS

  • Icon Telefon

    Telefon

    +49 6621 5076 0

  • Icon E-Mail

    E-Mail

    This email address is being protected from spambots. You need JavaScript enabled to view it.

  • Icon Uhr

    Montag-Freitag

    08:00–16:00 Uhr

  • Last updated on .

Electric dip
coating systems

Electric dip coating systems

Electric dip coating is an electrochemical process for coating metals that can be used for all submersible workpieces and is reckoned to be of particularly high quality, resource-saving and environmentally friendly. The paint ensures a hard-wearing surface with a very high level of corrosion protection and is used particularly in vehicle construction as well as in agriculture and forestry.

Depending on the polarity of the workpiece, electrocoating is divided into cathodic dipping (CDC system; workpiece acts as cathode) and anodic dipping (ADC system; workpiece acts as anode).

Advantages of coating
using electric dip coating

  • Resource- and environmentally friendly painting process

  • CDC and ADC systems

  • Even coating of the entire workpiece

  • Robust surface paint

  • High corrosion protection

  • Also suitable for complicated shapes with cavities

  • Can be combined with various top coats

  • High level of automation

  • KTL Tauchlackieranlagen

  • Abwasseranlage KTL Beschichtungsanlage

  • Digitaler Anlagenzwilling Tauchlackieranlage

  • KTL Beschichtungsanlage Fuer Grossteile

  • 20230621 100435

  • 20230711 160124

  • How CDC and ADC systems work

    The components are first cleaned in an immersion pretreatment line. During electric dip coating, the entire surface of the components is covered with an even film of paint. No shadows are produced, and even cavities or edges are coated cleanly and evenly. Following the painting process, the coating is sealed at approx. 180 - 220 °C and can subsequently be combined with other painting systems.

  • Dip coating systems from AFOTEK

    Within the dip coating segment, we supply conventional dip coating systems as well as CDC systems and ADC systems, including all peripherals, such as cycle lifting systems, ultrafiltration, VE rinsing and exhaust air purification. We rely on well-known manufacturers for our proven anolyte systems, dialysis cells and ultrafiltration components.

    Depending on customer needs, a powder coating line can also be integrated into the system concept.

    AFOTEK designs and develops state-of-the-art systems for CDC and ADC dip coating, tailored to the needs and components of customers. Particular attention is paid to the energy concept and heat recovery measures so that the system operator can operate his system cost-efficiently.

    The control and safety technology of the dip coating systems are also made by AFOTEK, thus guaranteeing total system support. When controlling the systems, AFOTEK relies on innovative Siemens S7 technology including TIA Portal and works with a digital system twin to visualise the control system, which makes error detection and elimination extremely easy and minimises downtimes.

CDC DIP COATING SYSTEM REFERENCES

  • Collini Gmbh

  • Giga Coating

  • Kaiser Gmb H Oberflchentechnik

Specialisations
at a glance

Automation and digital solutions

Ultra-modern and intelligent system solutions ensure that painting system operators can work profitably. In addition to transparent processes and digital documentation, robotic painting systems and handling robots ensure cutting-edge system technology in accordance with the Industry 4.0 standard. Interfaces to upstream and downstream ERP and/or MES systems round off the innovative control concept.

  • Robotics
  • Dashboard
  • Real-time simulation in 3D/material flow
  • Automation technology

    (MES, ERP solutions etc.)

  • PAINTING SYSTEMS

  • POWDER COATING SYSTEMS

  • DIP COATING SYSTEMS (CDC)

  • PRETREATMENT SYSTEMS

  • DRYING SYSTEMS

  • AFOTEK SHUTTLE CONVEYOR SYSTEM (ASF)

  • BIOLOGICAL EXHAUST AIR PURIFICATION SYSTEMS

  • DIGITAL SOLUTIONS

  • Icon Telefon

    Telefon

    +49 6621 5076 0

  • Icon E-Mail

    E-Mail

    This email address is being protected from spambots. You need JavaScript enabled to view it.

  • Icon Uhr

    Montag-Freitag

    08:00–16:00 Uhr

  • Last updated on .

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