Challenge
Visible components such as trim strips, B- and C-pillar trims, and roof rails made of steel and aluminium had previously been coated using multi-coat systems. These processes were material-intensive, resulted in long throughput times and required separate process control for each substrate. High paint consumption, complex reverse-side coating and the associated costs increasingly posed economic challenges.
- High paint consumption due to multi-coat systems
- Long throughput times in series production
- Different process control for steel and aluminium
- Complex reverse-side coating in separate passes
- Rising production costs alongside stringent appearance requirements
Solution
KSK implemented a licensed single-coat solid topcoat with a self-healing reflow effect. Combined with electrostatic application via a high-speed rotary bell, optimised coating of parts in a horizontal position and coordinated process control, this created a highly efficient overall system. The front and reverse sides of the components are coated in a single pass – regardless of whether they are steel or aluminium.
- Single-coat solid topcoat with self-healing reflow effect
- Electrostatic application via high-speed rotary bell and automatic spray guns
- Optimised horizontal coating
- Two-sided coating in a single pass thanks to innovative racking technology
- Uniform process control for steel and aluminium
Results
- Exceptionally smooth, high-gloss surfaces with a piano-black finish
- Significantly improved scratch resistance compared with previous systems
- Reproducible quality throughout the entire production run
- Reduced coating consumption and shorter coating times
- Significantly lower costs per component
