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Optimized paint processing for high-pressure technology

Hammelmann GmbH, founded 1949 in Oelde, Westphalia, is an internationally active manufacturer of high-pressure technology. The medium-sized company offers its customers customized solutions. In order to become even more effective in terms of material usage, time and quality when painting the pumps and systems produced, Hammelmann decided to invest in an electronic mixing and dosing system from WAGNER including paint supply, gun flush box and control system - implemented by long-standing service partner Oltrogge.

Less material consumption, more success

Hammelmann GmbH has been a manufacturer of powerful high pressure plunger pumps and cleaning systems for 75 years. Subsidiaries in the USA, China, Australia, Spain, France and Switzerland as well as 40 agencies ensure a global presence. The company employs 485 people at its headquarters in Oelde, Westphalia. They produce pumps and systems that are used worldwide in various sectors and industries, for example for cleaning heat exchangers, containers and pipelines as well as for paint stripping and cleaning metal surfaces in shipbuilding, gratings and storage tanks.

Hammelmann products are also in great demand for deburring engine blocks or maintaining bridges, roads and other structures. With an operating pressure of up to 4,500 bar, the systems are also used for cutting reinforced concrete, metal and other solid materials. Process pumps, which are used in the chemical and petrochemical industries and in the extraction of oil and gas, are another mainstay of the company. Hammelmann also produces pumps and systems for the hygienic conveying of high and low viscosity foodstuffs.

2k smart mixing and dosing system by wagner

Clear goals: Save material and time, expand capacity

Hammelmann GmbH needed to update its painting system for surface treatment in production. "We were already using a liquid coating system with electrostatic application and paint supply from WAGNER," explains Stefan Wickenkamp, Head of Steel Construction and Paint Shop at Hammelmann. "We are still very satisfied with the system components today. However, we have been mixing the material by hand for years, which has made us less and less efficient - both in terms of working speed and material consumption."

Reiner Feldkamp, service technician at long-standing service partner Oltrogge, recalls the start of the project and the customer's wishes and requirements: "It was particularly important to Hammelmann to be able to save material, i.e. paint, with the new solution. In addition, color changes should be possible in a shorter time. At the same time, the aim was to create the opportunity to expand capacities in the paint shop if required and to automate the production process in the long term."

After detailed consultation with Oltrogge, Hammelmann decided to invest in a WAGNER 2K Smart mixing and dosing system, including a gun flush box from Oltrogge. The existing GM 5000EAC electrostatic manual gun with the associated control unit was retained for the application, as it had already proven itself over many years. The WAGNER pumps in the paint supply system - Cobra 40-10 and Leopard 35-70 - have been replaced by modern models in the new system.

Optimized paint processing: More efficiency and quality

The 2K Smart electronic mixing system is suitable for all applications in which multi-colored 2K or 3K paints are processed. It can be used to process a wide range of workpieces from different application areas. Thanks to their compact, space-saving design, Hammelmann is now able to shorten production routes and optimize paint and flushing agent consumption.

The company also benefits from the quality of the new system. The dosage of hardener is adapted to different material flow rates using the adaptive injection system AIS. If the paint volume flowing through the system changes, it automatically ensures an optimum mixing ratio. The coating results are more homogeneous and the coating appearance is improved.

The GM 5000EAC electrostatic manual gun from the predecessor system continues to impress with its homogeneous spray jet and very high application efficiency, which saves a considerable amount of material. The pumps in the paint supply system are particularly reliable and ensure fast work with short flushing and color change times.

Hammelmann is delighted with the result: "Thanks to the automatic dilution and adjustment of the mixing ratio, we no longer have any manual mixing work. This gives us more process reliability in production and therefore for our customers," says Sebastian Voß, Head of Purchasing at Hammelmann GmbH. "This enables us to implement orders for our customers even more effectively and ensure their economic success in the long term. With the help of Oltrogge, we got an effective solution that was also smoothly integrated into our production process and can also be integrated into automatic systems in the long term."

Oltrogge is also extremely satisfied after the installation of the new system: "We are delighted that the customer is so happy with the result," says Kevin Schulze-Bockholt, Head of Surface Technology at Oltrogge. "The project also had an additional effect for us: We can visit the new plant with interested customers to demonstrate the benefits live."

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