Reducing energy consumption in powder coating systems

An energy efficiency package for powder coating systems with a monocycle can reduce energy consumption by up to 40 percent. Optimized air flow reduces the power consumption of the fan motor in the afterfilter.

Rising energy prices and the call for more sustainable production processes make it clear that anyone operating powder systems today cannot ignore the issue of energy efficiency. J. Wagner GmbH has a convincing answer to this: the Energy Efficiency Package (EEP), which is integrated into all Wagner powder coating systems with monocyclone.

Energy consumption in powder coating systems is largely caused by the extraction in the booth, piping and recovery system. The fan motor in the secondary filter, which can reach outputs of over 30 kW depending on the size of the system, is particularly important. This is precisely where the EEP comes in, which Wagner developed several years ago and which is now more important than ever: with a well thought-out air flow and optimized components that significantly reduce energy requirements.

At the heart of the concept is the specially developed EEP monocyclone. It separates the powder-air mixture, directs the exhaust air to the secondary filter and sifts the powder back to the guns. Its flow-optimized design results in significantly lower pressure losses than with conventional systems. As a result, the secondary filter requires a smaller fan motor. Up to 40 percent less power consumption is possible without sacrificing extraction performance. The flow-optimized monocyclone also improves powder recovery: the separation efficiency is increased by one to two percent, which means that more powder can be recovered and thus saved.

The specially shaped pipe between the cabin and monocyclone also helps to minimize the pressure loss in the system. The special shape, which differs from conventional piping on the market, significantly reduces powder deposits and powder wear. This protects the powder, improves the recovery quality and ensures a stable, clean color change process. Manual cleaning of the monocyclone interior during color change is generally no longer necessary, which further shortens the color change process.

If you want to get even more out of the system, you can opt for the optional EEP Plus extension. The system automatically detects when there are no components hanging on the conveyor - so-called hanging gaps - and then switches to ECO mode. During this time, the fan motor runs at a reduced speed, which further reduces energy consumption. As soon as components are detected again, the system starts up automatically. Depending on the production process, an additional 10 to 30 percent of energy can be saved in this way - without any intervention by the operating personnel.

Technology that pays for itself: With the Energy Efficiency Package and the EEP Plus extension, Wagner offers a pioneering solution for energy-efficient powder coating. For system operators, this results in a clear economic advantage: the lower energy consumption noticeably and sustainably reduces ongoing operating costs - and, according to the manufacturer, without compromising on process reliability or coating quality. (OM-10/25)