High-Precision surface treatment for the UK automotive sector

In the fast-paced world of automotive manufacturing, the quality of surface finishes on plastic components is a critical differentiator. For Formaplex Limited, a leading UK-based provider of lightweight component solutions, CALDAN implemented a state-of-the-art P&F160 floor conveyor system. This 158-meter installation is specifically engineered to handle the complexities of painting and curing large-format automotive plastics at their facility in the United Kingdom.

The Challenge: Handling large-format plastic components

The Formaplex project involved the transportation of various automotive plastic parts, with dimensions reaching up to 2,400 mm in length. To ensure a world-class finish, the system had to address several technical challenges:

1. Precise rotation control: For optimal paint coverage, parts required manual rotation within the spray booths and passive rotation during the oven curing process.
2. Accumulation efficiency: To maximize throughput, the system needed an efficient accumulation strategy, utilizing 90-degree parallel accumulation to save floor space while managing the cooling and buffering stages.
3. Temperature resilience: The conveyor components, specifically the cardan chain and 8-wheeled wagons, had to operate reliably within process temperatures reaching up to 100 degrees Celsius in the ovens.

The solution: P&F120 Power & Free Floor Conveyor System

The P&F160 Power & Free floor conveyor was selected as the ideal technology for this UK automotive application. Key technical features of the system include:

– Specialized wagon design: Each 8-wheeled wagon is designed to support loads up to 100 kg, providing the stability required for high-quality paint application on large exterior and interior components.
– Integrated 90-degree turning devices: The system features lockable 90-degree turning devices, giving operators full control during the manual spray processes and ensuring consistent results.
– Efficient throughput: With a cycle time of just 3.0 minutes, the system achieves a capacity of 20 wagons per hour, supporting the high-volume production requirements of the UK automotive supply chain.
– Robust cardan chain: The 158-meter system is powered by a high-strength cardan chain, ensuring smooth and reliable movement through both the manual spray zones and the high-temperature curing ovens.

Strategic impact on UK manufacturing

The Caldan UK conveyor installation at Formaplex has provided a robust and flexible platform for high-end plastic coating. By utilizing the P&F160 system, Formaplex has enhanced its ability to deliver premium finishes for Tier 1 automotive OEMs, reinforcing the strength of advanced manufacturing in the United Kingdom.

– Industry: Automotive plastics & lightweight components (UK)
– Application: Surface treatment and painting of plastic parts
– System Type: P&F160 Power & Free Floor Conveyor

Partner with the UK’s Floor Conveyor experts

CALDAN is the preferred partner for automated material handling in the British automotive sector. Our project with Formaplex demonstrates the precision and reliability of our P&F160 technology in demanding coating environments. Contact our UK team to discuss how our floor conveyor systems can optimize your automotive painting line.