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In times when energy prices continue to rise, energy-saving measures in production play a central role. Saving energy saves money and resources and contributes to more sustainability. Energy consumption in powder coating systems is primarily caused by the necessary suction within the powder booth, the piping and the recovery system. The biggest energy consumer in powder coating is the fan motor in the final filter, which, depending on the size, can have an output of 30 kW or more.
To keep energy consumption in the powder coating system to a minimum, we developed a special energy-saving concept back in 2016: The patented “Energy Efficiency Package” (EEP) is an essential component of our powder coating systems. To date, we offer the most energy-efficient powder coating systems on the market.
All WAGNER powder coating systems equipped with a monocyclone offer the Energy Efficiency Package. From the entry-level E-Line to the premium S-Line system.
The monocyclone separates the extracted powder/air mixture. The exhaust air passes through a pipe to the final filter and the powder is sieved and returned to the guns. Thanks to the flow-optimized design of the monocyclone, significantly lower pressure losses are achieved compared with conventional systems.
The final filter cleans the exhaust air coming from the monocyclone and ensures that no harmful particles are released into the environment. Thanks to the combination with the highly efficient monocyclone, a smaller motor is sufficient in the final filter to achieve a defined target value for the booth suction. This enables enormous savings of up to 40% of the energy requirement of the powder coating system.
The specially shaped pipe between the booth and the monocyclone also helps to minimize the pressure loss in the system. Compared to standard market solutions (image on the right), powder deposits in the pipe and powder wear are significantly reduced.
The monocyclone separates the extracted powder/air mixture. The exhaust air passes through a pipe to the final filter and the powder is sieved and returned to the guns. Thanks to the flow-optimized design of the monocyclone, significantly lower pressure losses are achieved compared with conventional systems.
The final filter cleans the exhaust air coming from the monocyclone and ensures that no harmful particles are released into the environment. Thanks to the combination with the highly efficient monocyclone, a smaller motor is sufficient in the final filter to achieve a defined target value for the booth suction. This enables enormous savings of up to 40% of the energy requirement of the powder coating system.
The specially shaped pipe between the booth and the monocyclone also helps to minimize the pressure loss in the system. Compared to standard market solutions (image on the right), powder deposits in the pipe and powder wear are significantly reduced.
Same air volume flow in the booth with up to 40% lower energy consumption of the final filter motor compared to conventional systems on the market.
Same air volume flow in the booth with up to 40% lower energy consumption of the final filter motor compared to conventional systems on the market.
Air volume flow | Standard design | EEP design | Savings per year (240 days, 8h, 30 ct/kWh) |
13,000 m³/h | 30 kW | 18.5 kW | 6,624 € |
17,000 m³/h | 37 kW | 22 kW | 8,640 € |
21,000 m³/h | 45 kW | 30 kW | 8,640 € |
25,000 m³/h | 55 kW | 37 kW | 10,370 € |
29,000 m³/h | 75 kW | 45 kW | 17,280 € |
The special design of the monocyclone and piping reduces the pressure loss and optimizes the air flow in the system. As a result, there is less powder wear and powder deposits. There are fewer fluctuations in the quality of the recovered powder.
The special design of the monocyclone and piping reduces the pressure loss and optimizes the air flow in the system. As a result, there is less powder wear and powder deposits. There are fewer fluctuations in the quality of the recovered powder.
In addition to the energy savings, the flow-optimized design of the monocyclone also increases the cyclone separation efficiency by 1-2 %, as more powder is recovered. Depending on the system configuration, the powder savings can be very significant - as in this example calculation:
In addition to the energy savings, the flow-optimized design of the monocyclone also increases the cyclone separation efficiency by 1-2 %, as more powder is recovered. Depending on the system configuration, the powder savings can be very significant - as in this example calculation:
Starting point | Cyclone efficiency +1% | |
Application efficiency on the workpiece | 30% | 30% |
Cyclone efficiency | 95% | 96% |
Powder output per gun | 180 g/min | 180 g/min |
Number of guns | 16 | 16 |
Powder loss | 10.4% | 8.5% |
Powder loss per work shift (7h) | 42 kg | 34 kg |
Powder loss per year (230 days, 4 €/kg) | 38,949 € | 31,159 € |
Cost savings | 20% |
Fewer powder deposits lead to less contamination, which increases safety during color changes. It is also not necessary to clean the interior of the monocyclone manually when changing colors.
Fewer powder deposits lead to less contamination, which increases safety during color changes. It is also not necessary to clean the interior of the monocyclone manually when changing colors.
With the EEP Plus, you can save between 10 - 30% energy additionally, depending on the production process.
The speed of the final filter motor is significantly reduced (ECO mode) in hanging gaps (when no components are hanging on the conveyor) - compared to coating operation and color change - which further reduces energy consumption during powder coating. Hanging gaps are automatically detected by the system. The system then automatically switches to ECO mode. As soon as the system recognizes the next components, the system is brought back to an operational state.
The EEP Plus is available as an option for the E-Line Plus, M-Line and S-Line powder coating systems.
Powder recovery system
Powder complete system
Powder complete system
Powder complete system
Powder complete system
Operation & control system
Full efficiency in one system - that's the WAGNER complete powder systems. Each available system offers a coordinated combination of high-quality components.
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Our products and systems for powder coating offer a wide range of applications, fast color changes and efficient process technology from feeding to powder recovery.
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Up to 40% less energy consumption in powder coating systems: Read the official press release on our Energy Efficiency Package.
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