A sanding process will produce high quantities of fine dust. The fine dust particles have a similar size as the sanding marks; they will therefore accumulate there and are very difficult to remove. A meticulous cleaning of the product surface is vital if after sanding the parts are passed on to a high-gloss coating process.
Intermediate lacquer sanding and fine dust
Normally, sanding machines have different cleaning devices such as compressed air nozzles or suction slots at their outfeed area. After a contactless cleaning process, however, large amounts of fine dust still tend to cling to the product surfaces. A great number of wiping procedures, too, cannot cope with the amounts of fine dust as the dust particles cover the filaments and saturate the brushes.
Air-assisted pre-cleaning
Wandres GmbH micro-cleaning has designed its Tornado Channel TKR 200 especially for cleaning procedures after sanding. Compressed air nozzles which rotate at high speed are the core of this cleaning module. These Tornado nozzles are synchronised and driven by timing belts. They rotate only at a few millimetres distance above the subject surface. Compressed air exits the Tornado nozzles with at several times the speed of sound. The compressed air detaches debris and dust particles from the surface propelling them towards the suction connections. Cleaning areas of the nozzles overlap, so that the entire width of the product surface along the channel will be cleaned very efficiently. This system will remove more than 90% of all fine dust particles.
Precision cleaning with linear brushes
For most sanded surfaces, the compressed air assisted cleaning with the Tornado Channel TKR 200 from Wandres will suffice to achieve the requested end quality. For high gloss surfaces, however, an even more exigent cleaning quality is requested. High gloss effects may be brought about much better with thin lacquering layers rather than with more compact coatings. Thin layers have much less lacquering material though that may compensate any fine dust irregularities. With high gloss surfaces it is therefore recommendable to combine the compressed air-assisted pre-cleaning process with a precision cleaning with linear brushes. During the latter, Sword Brushes use the patented Ingromat® system to bind and remove even the most minute particles and debris (see illustration 1). Micro-moistened brush filaments wipe crosswise across the product surface. Even the tiniest particles adhere to the brush filaments. The linear brush regenerates itself due to an integrated continuous self-cleaning mechanism.
Suitability for daily use
The Combi Sword Brushes combine the air-assisted and brush cleaning systems. This combination has passed the test at numerous customer sites with flying colours. Wherever Tornado Channels and Sword Brushes are used in modern production lines, particle-related rejections are normally drastically reduced. As a consequence, the thickness of lacquering layers could also be cut to a minimum. This development has positive repercussions on the product's quality especially with respect to high gloss surfaces. Companies can economise on lacquering materials and have less production downtimes. Working conditions, too, will improve, as much less dust particles contaminate the production surroundings. The combination of Tornado Channel and Sword Brush sets the stage for a low-cost and repeatable mass production of high gloss and high-quality furniture fronts. The system also scores with low operating and maintenance costs.