Details
UV Coating Line is a high‑speed, energy‑saving, and eco‑friendly automated system integrating precision spraying, infrared (IR) leveling, ultraviolet (UV) instant curing, and environmental protection. It is designed for high‑gloss, scratch‑resistant, and high‑hardness surface finishing on plastics, metals, glass, ceramics, and wood substrates. Adopting 1–10 seconds UV curing (vs. minutes/hours for thermal curing) and low‑VOC UV coatings, it delivers excellent surface performance while complying with strict global emission standards. Widely used in automotive parts, two‑wheeler components, consumer electronics, and vacuum metallization top/base coating.
Feature And Advantage
1. Ultra‑fast UV Instant Curing1–10 seconds full cure; line speed up to 320 m/min; no thermal drying oven needed; floor space reduced by 60% vs. thermal lines.
2. High‑hardness & High‑gloss SurfaceUV coating hardness ≥4H (pencil); 60° gloss ≥95%; excellent scratch, abrasion, and chemical resistance; adhesion Grade 0 (cross‑cut).
3. Superior Paint Utilization & Cost SavingsElectrostatic rotary atomizer achieves 85–95% transfer efficiency; saves 35–55% paint vs. manual guns; closed‑loop paint supply reduces waste.
4. Low‑VOC Eco‑friendly TechnologyCompatible with 100% solids / high‑solid UV coatings; VOC emissions reduced by 70–80% vs. solvent‑based lines; meets CE, GB 37822‑2019, and global standards.
5. Intelligent & Flexible ProductionPLC + HMI centralized control; auto part ID, trajectory matching, real‑time T/H monitoring, MES integration; quick color/model changeover (≤15 min); supports multi‑material and complex geometries.
6. Modular & Compact DesignExpandable stations/UV power; capacity 500–3,000 parts/day; spindle conveyor for round/irregular parts; easy integration with vacuum metallization lines.
7. Low Heat & Substrate‑friendlyUV curing temperature ≤60°C; no thermal stress or deformation; ideal for heat‑sensitive plastics (PP, ABS, PC/ABS) and thin‑wall components.
Specifications
| Process Section | Equipment / Parameter Item | Technical Specification | Remarks |
|---|---|---|---|
| 1. Pretreatment System | Degreasing Process | Water-based alkaline spray cleaning; 45±5°C working temperature; 3–5 min treatment time; residual oil rate on workpiece surface ≤0.03% | Removes mold release agents, grease, and surface contaminants |
| Surface Activation | Dual optional: Flame treatment / Low-temperature plasma treatment• Flame: 1200–1500°C working temperature, 50–100mm treatment distance• Plasma: 3–5kW rated power | Post-treatment substrate surface tension ≥42 mN/m; permanently improves coating adhesion on low-surface-energy plastics | |
| Electrostatic Dust Removal | High-pressure ion electrostatic + air shower combined cleaning; 8–12kV electrostatic voltage; dust removal efficiency ≥99.5% | Eliminates static-adsorbed dust and prevents film particle defects | |
| 2. Clean Spray Booth System | Climate Control | Constant temperature 23±2°C; constant humidity 60±5%RH; indoor cleanliness reaches ISO Class 8 | Ensures stable spraying environment and zero cross-contamination |
| Air Supply & Exhaust System | Top air supply + bottom exhaust structure; 8000–12000 m³/h circulating air volume; indoor negative pressure -15~-25Pa | No paint mist overflow; ensures operator safety | |
| Filtration System | G4 primary efficiency + F8 medium efficiency + H13 high efficiency three-stage filtration; filtration efficiency ≥99.97% for 0.3μm particles | Blocks dust particles and eliminates film pinhole/spot defects | |
| IR Leveling Zone | Independent closed leveling zone; 60–80°C working temperature; 3–8 min single leveling time; dust fall ≤1 particle/m³ (≥0.5μm) | Promotes paint flow leveling; prevents orange peel and flow marks | |
| 3. Robotic Electrostatic Spraying System | 6-axis Spraying Robot | Repeat positioning accuracy ±0.02mm; maximum arm span 1800–2500mm; supports offline programming and 3D trajectory simulation | Adapts to complex 3D curved surfaces of workpieces |
| Electrostatic Rotary Atomizer (Core) | No-load speed 30000–70000rpm (stepless adjustable); 60–100kV high-voltage electrostatic output; voltage fluctuation ≤3%; rated paint flow rate 100–500mL/min | Core equipment for ultra-fine atomization and high paint transfer efficiency | |
| Atomization Performance | Atomized paint particle size 10–20μm; ultra-fine and uniform atomization | Ensures smooth film surface and zero coarse particle defects | |
| Film Thickness Standard | • UV Primer: 15–20μm• UV Topcoat: 25–40μm• Overall film thickness tolerance: ±2μm | Meets high-precision coating requirements for high-gloss surfaces | |
| Paint Transfer Efficiency | ≥85% (electrostatic adsorption efficiency) | 35–55% higher than traditional manual air guns; greatly saves paint costs | |
| 4. UV Curing System (Core Unit) | UV Light Source Type | Dual optional: High-pressure mercury lamp (365nm main wavelength) / UV-LED lamp (385/395nm main wavelength) | UV-LED has longer service life and lower energy consumption |
| Rated Power | 80–120 W/cm; light intensity stepless adjustable | Adaptable to different coating types and curing requirements | |
| Curing Performance | Full polymerization curing time 1–10 seconds; line speed up to 320m/min | No thermal drying oven needed; greatly improves production efficiency | |
| Working Temperature | Curing zone surface temperature ≤60°C | Low heat impact; no thermal deformation of heat-sensitive plastic substrates | |
| Energy Saving Performance | UV-LED solution saves 70–80% energy compared with traditional mercury lamp curing | Greatly reduces long-term operating energy costs | |
| 5. Conveying System | Conveyor Type | Dual optional: Overhead suspension chain conveyor / High-precision spindle conveyor; with servo tracking system | Spindle conveyor is ideal for round/irregular rotating parts |
| Operating Parameters | Running speed 5–20m/min (stepless adjustable); single hanger load 30–100kg; conveying positioning accuracy ±0.5mm | Adapts to different production capacity and workpiece size requirements | |
| Working Stability | Supports 24-hour continuous unmanned operation; annual equipment failure rate ≤1.2% | Ensures stable mass production and delivery | |
| 6. Environmental Protection System | Paint Mist Treatment | Water curtain scrubber + high-efficiency bag filter combined treatment; paint mist purification efficiency ≥99% | Prevents paint mist pollution and meets workshop environmental requirements |
| VOC Waste Gas Treatment | Activated carbon adsorption / RTO regenerative thermal oxidation optional; VOC emission concentration ≤50mg/m³ | Fully complies with EU CE, GB 37822-2019 and other global environmental standards | |
| Noise Control | Whole line noise ≤75 dB(A) | Meets industrial workshop occupational health and safety standards |
Application Areas
Parts: Automotive trim, two‑wheeler fairings/fuel tanks, electronic housings, cosmetic packaging, vacuum‑metallized components, wood panels
Materials: PP, ABS, PC/ABS, steel, aluminum, glass, ceramic, wood
Coating Types: UV primer, UV clear topcoat, UV high‑gloss/matte finish, UV vacuum metallization base/topcoat
Honglichang Serve
Parts: Automotive trim, two‑wheeler fairings/fuel tanks, electronic housings, cosmetic packaging, vacuum‑metallized components, wood panels
Materials: PP, ABS, PC/ABS, steel, aluminum, glass, ceramic, wood
Coating Types: UV primer, UV clear topcoat, UV high‑gloss/matte finish, UV vacuum metallization base/topcoat
Certificate
- National High-Tech Enterprise: Leaders in innovative automotive coating systems.
- ISO 9001 Quality Management: Consistent, top-quality PP ABS spray painting.
- ISO 14001 Environmental Management: Eco-friendly car parts paint shop solutions.
- ISO 45001 Occupational Health: Safe operations for every automotive coating line.
- Three National Invention Patents: Cutting-edge PP ABS spray painting tech.
- Seven Software Copyrights: Smart automation for precise automotive polymer coating.
- 57 Utility Model Patents: Practical innovations for car coating efficiency.
- General Contracting Qualifications: Expertise in mechanical and environmental engineering.
FAQ
What is the biggest difference between UV coating and traditional thermal coating?
A: UV coating adopts photo-curing reaction instead of high-temperature baking. It achieves full curing within 1–10 seconds under UV light, with curing temperature ≤60°C. It features higher efficiency, lower energy consumption, no thermal deformation and much lower VOC emissions compared with thermal curing lines.
What materials are suitable for UV spraying?
A: The line supports ABS, PP, PC/ABS, nylon, metal, aluminum, glass and vacuum-metallized parts. For low-surface-energy plastics such as PP, plasma or flame activation is required to ensure Grade 0 adhesion.
Can UV coating achieve high gloss and matte finish?
A: Yes. It supports high-gloss, semi-gloss, matte, anti-fingerprint and hard anti-scratch UV finishes. The 60° gloss can reach ≥95° for high-gloss products.
Why need IR leveling before UV curing?
A: IR low-temperature leveling helps paint flow naturally, eliminate orange peel and spray texture, ensure uniform film thickness before instant UV curing, and avoid surface ripples or uneven gloss.
Power up your production with a smart painting line that works. Reach out to Honglichang for a custom solution and a free consultation. Let's talk!
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