What are the advantages of Wolfrayet Gas Catalytic IR systems? There are many features of Gas Catalytic IR ovens that are advantageous. They interact with each other in a way that further multiply into significant financial savings. The actual savings depend upon the required focus. This could be any one or combination of the following:
A typical Gas Catalytic IR oven requires 50% less space than an equivalent conventional convection oven. So, by replacing a convection oven with an equivalent size IR oven will logically double the output from the same available space. But, due to the 3:1 rule, there is multiplier effect that more than doubles the output from the same space. It's often referred to as the '3:1 Rule'.
The '3:1 Rule' is often quoted when considering Gas Catalytic IR technology. It means that curing takes place in one third the time that would be required in a conventional oven. So, if a conventional oven typically cures powder in 30 minutes, a Gas Catalytic IR oven would take only 10 minutes. This fact gives coaters the option to increase output using less than 50% of the available space.
A Gas Catalytic IR oven is designed to have zones which enables the correct amount of heat to be generated at the correct time. When a coated part enters an oven, the powder has to be brought up to 'gel' temperature very quickly. But once the polymeric crosslinking begins, less heat is required. WolfRayet ovens utilizes a PLC control system which enables the correct amount of heat to be emitted at each part of the curing process. These carefully created profiles can be created for different types of part, powder type and required line speed. Each profile can be stored and retrieved very quickly. This ensures that the oven is not wasting expensive energy, but operating at peak efficiency.
A conventional convection oven typically takes 45 - 60 minutes to come up to operating temperature. Compare this to a Gas Catalytic IR oven which takes 15 minutes. During planned stops in production, a conventional oven has to stay at full temperature. A Gas Catalytic IR oven can be put into 'Standby Mode', which is 20% of the full power mode. When an oven is in this mode, it takes only 2-3 minutes to come back up to full operating output.
A conventional convection oven requires large movements of hot air to acheive a cure. This means that dust easily becomes airborne and can land on a curing part. Also airborne dust tends to land on overhead conveyors and other horizontal surfaces. This will build up until it eventually dislodges and falls, often onto curing parts. Gas Catalytic IR ovens have much less air movement thus reducing potential dust contamination. Because the curing time is considerably reduced, there is less time for potential contamination. Overall, a Gas Catalytic IR system will consistently produce better quality coated parts. This means that the cost of rework and lost production time is reduced considerably.
