Industrial Paint Coating Systems
The objective of our paint coating services for any type of surface is to enhance key properties such as appearance, adhesion, wetting characteristics, corrosion resistance, wear resistance and scratch resistance, among others. To achieve this, we apply different industrial-scale coating processes, including immersion coating and powder coating, for a wide range of industrial sectors.
Liquid and Powder Paint Coating Systems and Processes
At Cabycal, we design and develop different industrial paint coating systems, mainly focused on the following types of paint coating solutions.
Liquid Paint Coatings
Immersion Coating: Cataphoresis or E-Coat
Cataphoretic coating consists of a dispersion of resins and pigments in an aqueous medium with a low solvent content (typically below 4%) and three basic components: demineralized water, cationic binder and pigmented paste. These components are incorporated directly into the immersion bath to compensate for consumption during the coating process, evaporation losses and drag-out.
By controlling these components, it is possible to regulate key coating parameters. At Cabycal, we design and manufacture complete cataphoresis coating installations for linear transport systems (overhead monorail conveyors) or P&F conveyors, incorporating immersion tanks, rinsing, phosphating and coating stages. This process can also be integrated into automated power-and-free systems with automatic loading and unloading.
All cataphoresis coating systems developed by Cabycal are fully automated and controlled using Industry 4.0 technologies, enabling full traceability, quality control and real-time process monitoring.
In addition, immersion coating is a high-performance system capable of coating both external and internal surfaces of parts. In general, cataphoresis installations increase efficiency in terms of cost, provide greater operational reliability and simplify maintenance.
Spray Application
Cabycal integrates paint application equipment from leading market brands, including electrostatic automatic air-assisted airless spray systems.
We design and supply complete installations that include paint supply systems, high-pressure pumps, paint recirculation systems and viscosity control. Our systems are suitable for both solvent-based and water-based paints and are designed to handle a wide range of viscosities.
For electrostatic application, the distinctive feature of this system lies in the electrostatic charging of the paint during spraying, which generates a high-voltage, low-intensity electric field. The electrostatic attraction between the charged paint particles and the grounded parts significantly improves transfer efficiency.
The most common application technologies include:
Rotary atomizers with high-speed bells up to 15,000 rpm
High-speed turbine atomizers up to 50,000 rpm, mounted on static or mobile installations
High-speed disc systems up to 40,000 rpm, integrated into Omega-shaped conveyors
These coating systems optimize paint application through centrifugal force and electrostatic attraction, achieving substantial paint savings and minimizing overspray.
At Cabycal, we integrate anthropomorphic robots for these applications. In automated installations and repetitive processes, robotic integration enables flawless industrial paint coating while significantly reducing paint consumption and waste.
To ensure continuous operation, we integrate paint mixing and circulation systems, pneumatic and electric pumping systems, and dosing units for single-component, two-component (2K) and multi-component paints, both solvent-based and water-based. Our systems maintain product agitation, color consistency and stable flow rates, while enabling fast color change and minimizing downtime.
Cabycal also develops installations specifically designed for the application of water-based paints.
Powder Paint Coatings
Immersion Coating
This process consists of fluidized-bed systems for the immersion of metal parts to apply powder coatings such as polyamide (nylon), polyethylene, and similar materials. The process requires preheating the parts in high-temperature ovens, followed by immersion in the fluidized powder bath. Depending on the application, this method provides high thickness coatings with excellent mechanical resistance.
Spray Application
These are high-performance powder coating systems that can be configured with different equipment depending on customer requirements. Solutions include manual powder coating booths, automatic booths, single-color or multi-color systems, high-efficiency recovery systems, and powder application equipment with advanced technology for optimal performance.
We also integrate automatic cleaning systems, manual and automated conveyors, part identification and programming systems using 2D or 3D vision, end-of-travel sensors to prevent accidental impacts, and full robotic integration with Industry 4.0-ready programming.
This type of powder coating system enables the application of anthropomorphic robotics with full programmability and adaptability to Industry 4.0 environments.
Other powder coating and surface treatment systems developed by Cabycal include aluminum passivation systems, pickling and passivation processes, among others.
For further information, please contact us.