Particle-free surfaces before lacquering

Intermediate lacquer sanding and fine dust

As a rule sanding machines are equipped at the outfeed with various dust extraction devices such as compressed air jets and a slot-shaped vacuum manifold. Following this cleaning process, however, large quantities of fine dust still remain firmly attached to the surface. Wiping the supposedly clean surfaces with a microfibre cloth finds evidence of residual fine dust. Even brush cleaning applications frequently fall short when confronted with the large amounts of fine dust created. Brushes are literally suffocated with fine dust accumulating on the surfaces of the filaments and clogging up the brushes. As any person who has ever tried to sweep snow with a broom will be well aware, after a very short time, the spaces between the bristles fill with snow and the broom slides over the snow instead of sweeping it up.

Air assisted pre-cleaning

Wandres GmbH micro-cleaning has developed the Tornado-Channel TKR 200 specifically to guarantee optimum cleaning results after sanding. At the heart of this air assisted cleaning module is a system of rotating compressed air nozzles, spinning at high speeds. The Tornado nozzles are driven and synchronized by a timing belt and the circular cleaning areas of the nozzles overlap. Positioned at equal height and very close to the product surface, the Tornado nozzles obtain an impact velocity of around 700 m/s. The air assisted cleaning application delivers entirely clean surfaces across the whole width of the Channel. Non-contact cleaning with this ventilation technology achieves top quality cleaning results, removing 90% of fine dust particles.

Precision cleaning with linear brushes

The innovative air assisted cleaning technology developed by Wandres will more than suffice to deliver the desired high-end quality finish for most surfaces after intermediate sanding. The trend towards high gloss finishes, however, requires the use of finer rather than thicker coats of lacquer to produce the ultimate high gloss look. Progressively finer coats require a lot less coating product which would otherwise compensate any fine dust still present. Applications such as these benefit from precision cleaning with linear brushes following the air assisted precleaning process. A newly developed Sword Brush with two linear brushes in parallel position works with the patented Ingromat® system to effectively remove even the tiniest dust particles from visible surfaces. Micro-moistened brush filaments wipe across the product surface, binding minute particles to the brushes which are constantly undergoing regeneration by means of a self-cleaning mechanism.

Handling continuous operations with ease

A modular cleaning unit combining ventilation technology and brush cleaning has passed the test with flying colours in continuous operations in industrial panel production. A process combining Tornado Channel and Sword Brush can significantly reduce reject rates arising from inclusions of particles in the lacquer coat. As a result finer coats can be applied which has a positive effect on the quality of the surface finish, in particular regarding surfaces with a mirrorlike high gloss finish. As a favourable knock-on effect, the amount of coating product required is minimized thereby lowering production costs, machine downtime is cut and concentrations of fine particulate matter in the production area reduced, thereby improving workplace health and safety standards. The combination of Tornado Channel and Sword Brush delivers cutting-edge cleaning technology for the cost-efficient and replicable mass production of high gloss furniture panels with a superior surface finish.