Chemicals and Coatings product profile

Surfin’s high tact CED production line:

An idea tool for seamless coating jobs
in the range of 600Amps-300V. This increases
connected load and power consumption
for customer and same results in up paying
higher expenses due to higher connected load.
However,the actual usage of @ 13%, as the cycle
time is 60 minutes and the voltage application
time is 8 minutes. This means rectifier remains
idle for most of the time.

The system designed by SURFIN is different

than a conventional method followed by most
of the designers who usually follow constant
voltage. Instead SURFIN haschosen system for
constant current and variable voltage.

After detailed calculations we reach to

conclusion that the average application current
required to coat 40 Sq m area of cabin in 8 minutes
is between 80 to 100 Amperes only as against
600Amps of initial spike in current with constant
voltage method. SURFIN has alsoinstalled current
Concept feedback system on the rectifier. The system
Designing Hightact Cathodic Electro- Deposition designed works in a manner that it starts applying
(Ced) Production Line (60 Min. Tact) With voltage from zero and increases gradually. Once
Optimised Connected Load The Component system receives feedback from the field that
current has reached the set value (in this case it
‘Offroad Truck Rollover Cabin ‘. was 100 Amp) it holds the voltage.
PAINT FILM THICKNESS : 30-40 Microns
PARAMETER VALUE Due to film build up and the resistance
offered system current starts dropping down
AREA TO BE COATED 40 Sq m
to @ 85 Amperes along with feed back to the
FILM THICKNESS 35 Microns minimum control unit. Post this feedback rectifier increases
PAINT SHADE GREY the voltage from the previous hold value till
TACT 60 Minutes current reaches to set value of 100 Amp. This is
maintained for8 minutes application time. After
COATING TIME 8 Minutes
completion of 8 minutes cycle rectifier is switched
BATH Nv 16% off automatically.

The Process: Typical voltage current graph against time is

In case of CED coating, standard process followed shown below.
is 3minutes coating time and fixed voltage
varying from 150V to 300V. In a typical dunk
type CED coating system DC voltage is ramped
up to set value within 10-15 seconds based on
the plant design. Due to application of voltage
initially current increases and then due to film
resistance it starts dropping down at the end of
the coating cycle. Standard cycle time for coating
is @ 3 minutes.

With above standard process the rectifier

capacity for this application would have been

34 B2B Purchase October 2019

Chemicals and Coatings product profile
Using constant current method
SURFIN has achieved following results
in favor of customer:
• Instead of constantvoltage,this constant
current system has reduced rectifier capacity
from @ 600 Amp-300V to 250 Amp -300V.
This has reduced the connected load
drastically and bringing down fixed power
cost.
• The constant current method achieved film
thickness variation of @ ±2.5microns on
entire area of 40 sq. meters, thus saving in
paint cost.
• Smooth finish of coating as the current
density maintained is almost constant
right from starting of the process till
completion of coating.
• Allowing flexibility of higher TACT through
36 B2B Purchase October 2019
increased coating time.
• Six-timeramp-up in future production
capacity using same rectifier.
• Optimization in power consumption through
reduced rectifier losses through reduction in
winding loss.
• Further the same equipment was successfully
tried out, under SURFIN’S supervision, for
larger cabin having 85 Sq m area in 8 minutes.
Application current band was increased from
80 – 100 Amps to 160 – 180 Amps. n
For more details contact
Mr. Umesh Phadke (Director)
Surfin Coating Systems Pvt. Ltd.
www.surfin-india.com