A mid-sized powder coating manufacturer in Spain required fine grinding of its high-performance epoxy and polyester powder coatings.
The main challenges of the project were the extreme temperature sensitivity of powder coatings, which tend to soften and agglomerate, and the customer’s requirement to strictly control the final particle size to d99 ≤ 100 µm.
In addition, the production capacity needed to remain stable at 150–200 kg/h.
Core Solution: Episches Pulver MJW Series Luftklassierermühle
To address the thermal sensitivity and strict particle size distribution requirements of powder coatings, we delivered an integrated grinding solution:
- Cold Air Circulation System:
The MJW Series classifier mill uses high-volume airflow to move material. This process simultaneously removes heat generated during grinding. We further optimized the system with a dedicated inlet air cooler. This ensures material temperatures stay below the softening point throughout the entire operation. - Integrated Precision Grinding and Classification:
Grinding and classification are combined in a single unit.
Operators adjust the classifier wheel speed via variable frequency control. This allows them to hit the d99 ≤ 100 µm target precisely without stopping the machine.
This eliminates oversized particles and improves surface smoothness after coating. - Low Energy Consumption with High Output:
For small-batch, multi-grade production at 150–200 kg/h, the MJW system features a quick-opening design.
This allows thorough cleaning during color or formulation changes and effectively prevents cross-contamination.
Comprehensive Consulting and Engineering Services
- Process Flow Definition:
We defined a complete process flow based on the customer’s layout in Spain. This system integrates feeding, grinding, cyclone separation, and dust filtration. - Plant Layout and Civil Engineering Support:
We also provided a preliminary layout to ensure the installation meets European safety standards.
Workshop ergonomics and material flow were also optimized. - On-site Technical Supervision in Spain:
Our senior engineers traveled to the site in Spain. They supervised the installation and managed the full system commissioning. During their visit, they conducted on-site training to help operators optimize process parameters. As a result, the plant maintains a stable output of 200 kg/h, even during high summer temperatures.
Project Results
- Product Quality:
The final powder consistently achieved d99 ≤ 100 µm, with uniform particle size and excellent coating performance. - Fast Color Change:
The optimized internal chamber design reduced cleaning time by 30%, significantly improving flexibility for multi-product manufacturing. - Turnkey Delivery:
From initial sample testing at our test center to on-site commissioning overseas, the entire project was successfully completed within the planned budget and schedule.