Redhill Manufacturing has made a significant leap forward in its production capabilities with the unveiling of a cutting-edge powder coating facility. This major investment underscores Redhill’s commitment to enhancing operational efficiency and product quality.
The new facility features two expansive powder application booths, each measuring 5m x 4m, and a large 12m x 2.5m oven, all connected by a sophisticated 134m track system. The facility’s standout feature is its ‘power and free’ design, a state-of-the-art system that revolutionises the powder coating process.
In the ‘power and free’ system, a continuously powered track at the top works in tandem with a PLC-controlled free track below, equipped with flight bars on rollers. This advanced setup ensures that the PLC system always knows the precise location of each flight bar, allowing for seamless and efficient movement of powdered products into the oven. The system minimises door opening times, significantly reducing heat loss and enhancing energy efficiency.
Powder-coated products wait at the oven door until space is available inside. The doors open automatically to allow the flight bar with the product to enter, and close immediately after. During door operation, the burner power decreases to conserve energy, then quickly returns to optimal levels once the doors are closed, maintaining the correct baking temperature.
Video sped up for demonstration purposes
The dual booth system leverages the power and free mechanism to its fullest potential. Given the variety of products Redhill manufactures, powder application times can vary from 2 to 20 minutes. After powder application, operators simply press a ‘finish’ button to send the powdered product towards the oven.
Once the product is baked, the exit doors open automatically, and the product is transported to the assembly area. This automated process reduces manual handling, enhancing both safety and efficiency. After cooling, products are promptly assembled, wrapped, booked for transport, and loaded onto trailers, ready for collection by Redhill’s trusted transport partners.
This new facility represents a significant milestone for Redhill Manufacturing, reflecting the company’s dedication to technological advancement and superior product delivery. By streamlining the powder coating process and integrating energy-efficient practices, Redhill Manufacturing continues to set the standard for excellence in the industry.
