ARENA

CPP

Proservicetech is expert in foundry equipment and solutions to optimize not just the coating but also drying, filtration, pumping of the coating and handling of cores and moulds. In case you are evaluating a CPP for dipping: visit also the page of ARENA All-in-ONE

CPP Coating Preparation Plant

CPP (Coating Preparation Plant) is the stand-alone unit for the automatic coating control and preparation for any type of foundry coatings (alcohol and water based coatings) without the use of operators. Secure your process of dipping, flow coating or spraying by a CPP Coating Preparation Plant: it is fully traceable and reliable, 100% independent by operator and ready for Industry 4.0. Since 2004, Proservicetech has installed more then 150 equipment using this technology.

Why Proservicetech and CPP?

  • Proservicetech takes care the engineering, programming, assemblying, installation and service of the CPP without using third companies.
  • Multiple coating controls and solutions to cover all customer needs.
  • Coating control systems can be tested in water in short time (mandatory for controlling sensors in foundry)
  • CPP is almost maintenance free (< 5 min / month)
  • Integration: Arena E-PUMP, Coating pressurized vesse CPV , Vibro-filter
  • CPP is designed to automatize and simplify the dense coating dosing according the way it is delivered (drums, containers or trucks, …)
  • Coating control completely independent by the operators
  • CPP works perfectly with all foundry coatings (Durrans, ASK Chemicals , HA Huttenes Albertus , FOSECO , etc..) without signing contracts for foundry consumables.

Main defects related to coating

The coating layer thickness is directly related to the features of the coating and to the cost and quality of the castings, for this reason its consistency is a must. Coating contamination by sand and dried coating, bacterial attacks are also cause of casting defects, re-work or scraps. In the next chart, the main defects are linked to possible causes.
Sometime, the real source of these defects is difficult to be determined. Veining is the best example. Sand grain size and grain particle size distribution, compaction, metal pouring temperature, type of moulding material and coating features are just some of the variables responsible of this common defect. Proper application of a “high quality” coating is an effective method to cover, reduce or even solve problems related to this casting defect. Even the most-sophisticated coating needs to be kept at constant and predictable conditions, otherwise the coating itself becomes the possible source of those defects.

From traditional methods to ProServiceTech solutions

Traditionally the foundries use several methods to check the coating, the most common ones are:

  • Ford or DIN cups (viscosity),
  • Baumè stick (Baumè),
  • Weight / volume (density) in laboratory.

The main limits of those methods are:

  • Dependent on the skill of the operators
  • Batch measurements
  • Very temperature dependent (Viscosity)
  • Measurable in lab and not in foundry
  • Manually recorded on paper

Unreliable coating measurements make the coating layer thickness inconsistent and unpredictable. Density is definitively more closely related to the solid content responsible for a layer build up and then to the final dried coating layer, that’s why we have developed the Density Sentinel: a continuous monitoring densimeter used as the core for all our CPP equipment: CPP (tailor made and Smartline) and dip tanks ALL-in-ONE.

Density Sentinel

The ProServiceTech branded densimeter and the core of our control system, continuously monitors the density of the coating. The probe is in contact with the coating while it is deposited into the preparation tank to detect even minor variations in the density of the coating.

The Density Sentinel is the main control, as it is standard in all CPP’s including the standard CPP Smartline range. The Density Sentinel probe is easily removable for quick testing. In fact, its accuracy can be tested by simply placing the probe into water. In less than two minutes the results of the test can be saved on the database for audit control purposes.

The density measured in equipment utilizing sensors which are on the side of the preparation tank or with the load cell / level control method (an indirect method of calculate the density) cannot be tested without draining the preparation tank first. All controlling sensors must to be periodically checked.

Dried coating adheres to the inside the preparation tank, tools forgotten on top the preparation tank during maintenance, vibrations, sedimentation due to no or insufficient mixing …these are just some of the issues which can influence the accuracy of the of the density if measured indirectly by utilizing the load cell and level control method.

CPP’s main options

Viscosity Sentinel, ProServicetech branded viscosimeter. It allows batch automatic measurements of viscosity taking the sample of coating directly from the preparation tank using a standard Ford B cup or DIN cups. The Viscosity Sentinel includes the automatic cleaning of the cup after each measurement. Viscosity control can be useful to detect and return an alarm in case of bacterial attacks on water based coatings or in case the foundry is familiar with this method of coating control.

WLT: Wet layer thickness control. Some “lost foam” foundries, using high dense coating (coating layer thickness up to 2 mm), uses to dip a stainless steel plate into the coating. Changes of coating properties are related to changes of the weight of the sample covered by the coating. Proservicetech has fully automatized and integrated this concept to the CPP, measuring the coating layer thickness by laser control as complementary coating control of the Density Sentinel.

UV water treatment: water coating can be contaminated affecting a lot the coating features and causing defects as explained in the previous paragraph. Before dosing the water into the CPP for the automatic density correction, the water is many times recirculated in a closed loop passing through a high-efficiency UV lamp. For each single passage, 99% of the microorganism are destroyed limiting the need of chemical additions into the coating and the costs to waste the infected coating and to empty and disinfect the equipment.

CPP Smartline

Standard, Simple, reliable, ready.

If you are looking for a simple solution capable of matching the all the previously mentioned features of the ARENA CPP Coating Preparation Plant, but with a standardized design and that quickly pays for the initial investment, CPP Smartline 300 and 600 is the answer.

They are designed to be space-saving with ergonomic design and low-maintenance requirements. Yet flexible enough to be adapted to your existing process (flow coating, dipping or spraying). CPP Smartline can be commissioned in 1 day without ProService technicians, thanks to the “plug and play “features.

The CPP Smartline 300 and 600 are provided with a Density Sentinel as well as coating temperature monitoring.

Other benefits

  • Short delivery time
  • Easy unpackaging and installation at customer side
  • ATEX Certified for alcohol based coating
  • User friendly

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Case studies

Automatic coating preparation in automotive foundry

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