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Shotblast andPainting Systems

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The complete KALTENBACH program for pro�le and beam processing

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The name speaks itself: In the Sprint shot blasting plant, pro�le beams and

sheets are thoroughly and quickly cleaned. Double sheave turbine wheels

provide an optimum shot blasting result with highest �ow velocities and

lowest blasting abrasive application. The maintenance of the plants can also be

done quickly because the systems are designed for easy access and easy

replacement of worn out parts.

Applications: steel fabrication, steel service center, wage-ladders, machine construction, automotive sector, crane manufacturer, shipyard, etc.

Sprint 1504, Sprint 1506, Sprint 2506, Sprint 3008

Shotblast Systems for Beams and Plates with Optimum Cleaning Effect

The Sprinter

Advantages at a glance � Passage range (b x h): Max. 3.000 × 650 mm

� 4 to 8 turbines (11 kW each)

� Suitable for a throughput of from 10,000 to 20,000 tons per year

� Triple housing (steel / manganese steel / exchangeable manganese-steel internal lining)

� Maintenance and user friendly

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Having less is actually not desirable. But as far as maintenance is concerned,

everyone looks for less maintenance in the production process. The plants in

this series also focus on keeping everything „less“: less colour consumption,

less contact points, only one operation for the all round painting.

And therefore less time, less emissions, less cleaning and less maintenance.

There is only one point in which it is clearly more: the degree of automation.

The Maintenance Free One

Advantages at a glance � Passage range (b x h): Max. 4.100 × 700 mm

� Low paint consumption due to optimum spray gun concept

� Complete painting in a single pass

� Minimized material contact points with chain conveyor

� Use of water-soluble or solvent-based paints

� Low cleaning and maintenance times

KPC 1504, KPC 2504, KPC 3004, KPC 4004

Painting and Drying in a Single Package

Applications: steel fabrication, steel service center, wage-ladders, machine construction, automotive sector, crane manufacturer, shipyard, etc.

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Technical Data KPC 1504 KPC 2504 KPC 3004 KPC 4004Working range mm 1.500 x 600 2.500 x 600 3.000 x 600 4.100 x 600

working range Pro�le mm 1.000 x 420 2.500 x 420 3.000 x 600 4.100 x 420

working range Plate mm 1.500 x 80 2.500 x 50 3.000 x 40 4.100 x 30

Passage range mm 1.600 x 700 2.500 x 700 3.100 x 700 4.100 x 700

Number of spray guns 4 - 12 4 - 12 4 - 12 4 - 12

Coating System• High-pressure pump for paint• 200-litre drum with mixer• Drum lid with all necessary connections

(e.g. paint extraction device)• Pneumatic mixing-device lifter for easy

drum change • Continuous-�ow heater for consistent

paint temperature

Spray Guns• Spray guns apply paint to �nished parts

using an airless method • Clogging of the feed and discharge lines

is avoided through the continuous circu-lation of paint in the system

• Automatic height adjustment of the upper spray guns through photoelectric beams for optimum, economical paint application

Painting System• Two movable spraying bridges for positio-

ning spray guns (4 to 12 units)• Width of the spraying process is

adjustable • Automatic adjustment of the spraying

stroke to the feedrate• Bi-lateral optimized air�ow ensures

uniform application of coating • Low paint loss

KPC 1504KPC 2504KPC 3004KPC 4004

Applications: steel fabrication, steel service center, wage-ladders, machine construction, automotive sector, crane manufacturer, shipyard, etc.

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L o g i s t i c + P r o c e s s C o n t r o l

Huge potential for increasing e�ciency in steel machining

We know how: KALTENBACH Logistic + Process Control

Everything in Motion

Customer requirements

• Plate processing• Profile processing • Tube processing

• Sawing• Drilling• Stamping

Planning Logistics

Production process

• CAD/CAM-Systems• Data processing

• Transport• Storage• Handling

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The automatic production control with LPC (Logistic Process Control) systems is already widespread in the manufacturing industry. Up to now in steel machining, however, only stand-alone solutions have been implemented in steel construction and the steel trade and these only automate individual machining steps. As one of the �rst suppliers to do so, KALTENBACH has now developed the KLPC (KALTENBACH Logistic Process Control) system which fully automates all machining steps – such as sawing, drilling, �ame-cutting, coping to shotblasting and painting – as well as the transport of the work piece between the respective machining processes, and visualises them in real time.

Via the DSTV interface, the KLPC system can adopt CAD/CAM data directly from higher-level ERP systems. At the same time, it visualises and reports the processing status of each job in real time back to the ERP system. The production manager thus gains for the �rst time a complete overview of the current processes in the machining and thus optimises existing machine capacities and the utilisation of production.

With the KLPC system, KALTENBACH is heralding a new era in steel machining. On the one hand, it o�ers huge potential for increasing e�ciency with the automation and optimisation of processes.

On the other, it creates the prerequisites in the �rst place for capturing the entire machining process, visualising it and thus gaining a detailed overview of it. Every company that uses KLPC can thus draw up more comprehensive and detailed plans and generate a clear competitive advantage with this.

How the right material and

associated information reaches the right

location at the right time and how, when

and where the current process data gets

reported back?

Key issues

• Shearing• Coping• Shot Blasting

• Painting• Measuring• Transport

Production process

Logistics Construction site

• Transport• Storage• Handling

• Fastening• Mounting• Handling

Keep it Flowing !

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Advantages at a glance � Highest accuracy and productivity

� All from one source – for highest production reliability

� Modular and future-proof system

� A variety of automation levels from semi to full automation for complete processing lines

� Heavy and robust design

There’s no production without transport equipment. Sturdy roller conveyor

systems and cross transport systems guarantee an e�cient �ow of

materials in plate and steel processing. An extensive range of measuring

equipment generates full �exibility and required dimensional accuracy.

Cross Transport by Means of Drag Chains• Material stock in heavy-duty steel

construction• Sliding rails of synthetic material

(polyamide) for low-noise material cross transport

• Drag chains with transport claws• Drive system with continuously-variable

frequency-controlled gear motor

Cross Transport by Means of Lift-and-Carry System• Hydraulic liftable and lowerable lifting

beams running in both directions

• Drive system with continuously-variable frequency-controlled gear motor

Conveyor Roller System• Modular Expandable

• Executed in welded construction with maintenance-free, ball-bearing conveyor rollers of solid material

• Roller-conveyor drive on the feed and removal sides with frequency-controlled gear motor

Fully automatic Plate Processing centre• Automatic part removal and sorting

• Flexible programmed sorting location

• The size of the sorting range can be customised

Transport & Measuring

Efficient Flow of Materials is the Basis for Ultimate Productivity

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T13-Silencer• Contributes to enhanced occupational

safety and the protection of personnel and the environment

• Low-Noise Material Cross Transport

• Fully-automatic control

Marking System • Fast marking process for applying letters

and numerals

• Up to 22 characters without material movement

• Can be integrated into fully-automated handling processes

• Imprint still clearly visible after galvani-zing or painting

Contour Marking• Application of reference boundaries for

welding add-on pieces

• DSTV-Data import

• Use of high-speed carbide tools

• In addition to the three drill axis - marking from the bottom (4th axis)

Pusher Measuring System • Positioning drive through servo motor

with absolute rotary encoder

• Automatic NC positioning via machine software

• Hydraulic height adjustment for measu-ring various pro�le cross-sections

Length Stop Measuring System• Positioning drive through servo motor

with absolute rotary encoder

• Automatic NC positioning via machine software

• Rapid pivoting of the squaring arm

Autosorter• Process-assured full automation of the

feed side in pro�le handling

• Variable sorting positions possible

• For parts with mitre or straight cut from a length of 50 mm and up to a width of 1000 mm

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KALTENBACH sets new standards in the area of customer service: Remote

maintenance of all equipment ensures the fastest possible repair in case of

malfunction, and therefore the highest possible equipment availability.

Our specialists can be reached via a service hotline that o�ers professional

support worldwide. A dense network of national and international service

partners in over 40 countries ensures the presence at short notice of a skilled

expert when needed. Our parts service ensures that users can get the

spare parts they need for their machines even after many years.

Advantages at a glance � Over 150 service technicians are available at more than 40 locations worldwide

� 1st level support through the local service organization

� 2nd level support through the specialists at the service helpdesk

� INITIAL ASSEMBLY: Consulting, Project planning, Organization, On-schedule, professional assembly/initial operation, Training

� Breakdown prevention through maintenance contracts (preventative maintenance)

� Worldwide express delivery of necessary replacement parts and tools

“From practical experience – to be put to practical use!“

A Service Network that is there for You – Right from the Start!

The Originals

Service

Find your local Service Partner:

www.kaltenbach.com

Originale die passen!

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Tools for Drilling Machines Saw Blades Saw Bands

Additives and Coolant

Original KALTENBACH-Tools: Assemble and produce

Tools

+49 7621 175-241spareparts@

kaltenbach.de

Original Spare Parts forKALTENBACH/Gietart Shotblasters

To ensure a smooth production process a shotblaster should be

maintained regularly. We would be pleased to help you with this!

We can o�er you the complete package, directly from the

manufacturer:

� original spare parts

� service

� maintenance

Sparepartsfor Shotblast

Systems+31 74 2 452 260

spareparts@ kaltenbach-sps.nl

� repair

� assembly

� consultancy

Order hereAll Information on our Homepage

Robotic Coping Machines

Band Sawing and Circular Sawing

MachinesDrilling

Machines

Measuring Systems

Shotblast system

Punching/Shearing Machines

Plate Processing CentersPainting

System

Transport Systems

Robot Welding System

Kaltenbach GmbH + Co. KG PP.O. Box 17 40 D-79507 Lörrach, Germany Blasiring 4 D-79539 Lörrach, Germany

Phone: +49 (0) 7621 / 175-0 Fax: +49 (0) 7621 / 175-477

info@kaltenbach.de www.kaltenbach.com