Power & Free conveyor system

Key features of Power & Free systems:

Powerful performance:

The route of the Power & Free conveyor allows for inclines and declines, such as those required for A-ovens.

Maximum flexibility:

The flexible arrangement of conveyor flows allows coating processes to adapt to space requirements. Conveyor routes can be separated and merged as needed.

Suitable for any environment:

Power & Free systems perform well under extreme conditions, including high temperatures, dirt, or moisture.

Durability:

The wear-reducing design ensures a long lifespan for Power & Free systems.

Intelligent networking:

Thanks to smart integration with system controls, sorting routes can be easily incorporated.

Ergonomic design:

Lift and lowering stations at loading and unloading points simplify the handling of workpieces.

Technical data:

Weights:
From 10 kg to 10,000 kg
We offer customized solutions for heavier weights.

Speeds: Continuous operation

Temperatures: Up to 250°C

Control:
Comprehensive control systems designed by e. Luterbach AG to eliminate unnecessary interfaces.

Integration/Connectivity:
The SmartMES by e. Luterbach AG ensures seamless data exchange with any ERP system.

Circular conveyors

Key features of circular conveyor systems:

Continuity

The compact, self-contained system is ideal for tight spaces, making it suitable for hard-to-reach areas.

Modular design

The modular structure allows for easy expansion and adaptation to changing production workflows.

Space efficiency

Optimal use of space with minimal space requirement.

Economic efficiency

The most economical solution for processes with constant cycle times.

Custom hangers

Tailored hanger designs for single components or collective hangers.

Technical data:

Weights:
From 10 kg to 1,000 kg
Custom solutions available for heavier weights. Contact us for details.

Speeds:
Continuous operation

Temperatures:
Up to 250°C

Control:
Comprehensive control systems designed by e. Luterbach AG to eliminate unnecessary interfaces.

Integration / Connectivity:
The SmartMES by e. Luterbach AG ensures seamless data exchange with any ERP system.

Manual sliding systems

Key features of manual conveyor systems:

Modular design

Production changes can be quickly accommodated by simply modifying the existing conveyor system.

Low maintenance

The simple technology makes the conveyor system very low-maintenance.

Automation

Manual conveyor systems can be automated later using the Power and Free system.

Ergonomic design

A well-designed manual suspension track system enhances your company’s ergonomic concepts for employees.

Complete solutions

We are happy to support you with customized complete solutions for your optimal material flow or integration into existing coating processes.

Technical data:

Weights:
From 10 kg to 3,000 kg
Custom solutions available for heavier weights.
Contact us for details.

Temperatures:
Up to 250°C

Small, smaller, conveyor belt technology

Key features of our conveyor belt technology:

High throughput

Optimal belt utilization enables an enormous flow rate of workpieces.

No hooks, no stripping

Eliminates the need for hooks that require tedious stripping.

Proven belt technology

Our in-house produced metal belts for powder application and transfer onto oven belts via knife edges have been tested for years and are unique in the market.

Temperature resistant

Ultra-thin, temperature-resistant teflon belts are used in oven areas.

Total control

All belts are position-controlled to ensure track accuracy.

Innovative transitions

Innovative technology allows small parts from 10mm diameter to be transferred from one belt to another.

Innovative turning technology

Workpieces can be turned on the belt during the continuous process using innovative turning technology.

Drive and tension technology

Belts are operated using proprietary drive and tension stations.

Unique conveyor technology in coating:

Developed by our subsidiary SFB AG in the 1990s, this conveyor technology has been continuously improved over the past 30 years and is used globally across various markets.

Technical data:

Workpiece dimensions:
Starting from 10mm in diameter

Belt dimensions:
Width: 400mm – 1000mm
Length: Endless

Types: 
– Metal belts
– Antistatic Teflon belts
– Slip-resistant PVC belts

Throughput: 
Up to 170 million parts per year/shift

Applications: 
Globally across all markets

Typical applications: 
– Ferrite rings
– Magnet rings
– Nanoceramic rings
– Balancing weights
– Parking sensor housings
– Pipe clamps
– Undergarment parts
– Saw blades
– Handles
– General automotive parts
– General bulk materials

Production integration:
Automated loading and unloading integration or inline integration into existing production processes is possible.

Paint booths in systems

HIGH DEGREE OF AUTOMATION

From automatic part recognition to coating with multi-axis robots, there are no limits to what we can achieve.

REPORTING CAPABILITIES

With our intelligent MES system, all processes can be monitored and reported as needed, including remote access options.

PROCESS RELIABILITY AND QUALITY:

We ensure process safety across all areas, maintaining high-quality standards even for complex applications.

COATING PROCESS:

The level of automation in the coating process can be tailored to specific customer needs. Even semi-automated systems, such as those using manual overhead conveyors or partially automated ovens, are possible.

HIGH THROUGHPUT:

Automation allows for maximum utilization of hangers, significantly boosting throughput.

CONVEYOR TECHNOLOGY:

Integrated conveyor systems deliver parts in optimal arrangements to defined processes, ensuring an efficient workflow and maximum throughput.

COATING APPLICATION:

Our systems apply solvent- or water-based coatings using cutting-edge technology provided by our trusted partners. Flexible color change systems are a standard feature in all advanced installations.

 

We integrate the following processes seamlessly into our systems:

– Degreasing / Cleaning
– Flash-off drying
– Liquid coating application
– Color change systems
– Flash-off zones
– Drying ovens
– Cooling zones
– Conveyor technology
– Robotics

Technical data:

Core components:
– Fans
– Filter systems
– Heating
– Heat recovery systems
– Humidification
– Cooling / Dehumidification
– Exhaust air treatment (e.g., RTO, air scrubbers)

Materials:
Galvanized steel
Coated steel
Stainless steel (1.4307 and 1.4404)
Plastics like PPs

Air volumes:
 As per DIN EN-16985 standards

Filter systems:
– Coarse dust filter ISO coarse 40% (G3)
– Machine protection filter ISO ePM10 50% (M6)
– Fine filter ISO ePM1 70%
– HEPA filters up to H14
– Air scrubbers

Heating options:
– Electric
– Heating water
– Gas (direct/indirect)
– Oil (indirect)
– Thermal oil

Heat recovery options:
– Static plate heat exchangers (up to 65% efficiency)
– Rotary heat exchangers (up to 85% efficiency)
– Sorption regenerators (up to 85% efficiency, including latent energy/moisture recovery)
– KVS systems (up to 45% efficiency)
– Heat pumps

Humidification options:
– High-pressure humidification with osmosis water
– Ultrasonic atomization
– Steam humidification

Large-capacity spray booths

Full flexibility:

With spacious designs and zone-controlled air supply and exhaust systems, we provide complete flexibility to meet every customer requirement.

Superior quality:

Equipped with optional floor extraction systems, our booths can handle even the most demanding applications, such as those required in the aerospace industry.

Maintenance-friendly:

Even the largest booths are designed for optimal maintenance accessibility, ensuring user-friendly upkeep.

Standards-compliant:

All our large-scale booths are built to meet current en standards, guaranteeing compliance and safety.

Energy efficiency:

Innovative energy-efficient designs ensure minimal operating costs, even for oversized applications.

Heavy-duty capabilities:

Heavy-duty components can be safely and precisely prepared for the painting process using advanced conveyor and handling systems.

Technical data:

Workpiece dimensions:
Length: 10m – 100m
Width: 5m – 50m
Height: 3m – 10m

Application technology:
– Wagner
– Graco
– Devilbiss
– etc.

Filter systems:
– Dry filter systems with the e. Luterbach triple filtration system
– Sidewall or floor extraction options available

Ventilation systems:
– Custom ventilation units tailored to your needs
– Energy efficiency through heat recovery systems
– Selectable heating systems to suit operational requirements

Automated powder coating

High degree of automation:

From automatic component recognition to coating using a painting robot painting robots, there are no limits.

 

Complete process:

An automated powder coating system covers the complete powder coating process.

 

Total monitoring:

Using an intelligent MES system, all desired processes can be monitored and reported as required (also remotely).

 

Process reliability:

Process reliability in all areas enables a high standard of quality, even for delicate applications.

 

Conveyor technology:

Process-integrated conveyor technology brings the desired parts to the defined processes in the ideal arrangement to achieve an optimal workflow, with the highest possible throughput.

 

Powder cycle:

Powder recovery is carried out using the latest technology from our partners. Flexible color change systems are naturally part of a state-of-the-art system.

 

Technical data:

Usual dimensions:
Length: 1m – 10m
Width: 0.1m – 2m
Height: 0.5m – 3m

Other dimensions can be discussed.

Application technology:
– GEMA
– Wagner
– MS
– Nordson

Integrated processes:
– Degreasing / Cleaning
– Adhesive water drying
– Powder coating
– Powder recovery
– Gel coating
– Powder combustion furnace
– Cooling zones
– Conveying technology
– Robotics
– etc.

Horizontal powder coating

POWERFUL THROUGHPUT!

With the optimum belt configuration, the system can be perfectly utilized and an enormous throughput can be achieved.

 

COMPLETELY MODULAR:

Depending on the workpiece dimensions and requirements, the system can be adapted to customer needs in various details.

INNOVATIVE EXTRACTION TECHNOLOGY:

Cleaning the belts and undersides of the workpieces using an innovative extraction system achieves the highest quality results.

BELT TECHNOLOGY:

The metal belts produced in-house for powder application and the transfer to the oven belts using knife edges have been tried and tested over many years and are unique on the market.

POWDER RECOVERY:

The overspray on the conveyor belt is completely recovered. Thanks to our partners’ state-of-the-art powder processing and powder application technology, we are also at the highest technical level in this area.

OVEN TECHNOLOGY:

The energy-efficient powder curing ovens are mostly electrically operated and equipped with an IR boost. On request, the ovens can also be heated with gas or oil.

CLEANING:

The system can also be equipped with a cleaning system with belt on request. Contact us to find out whether your parts are also suitable for this.

UNRIVALED SYSTEM TECHNOLOGY:

Our subsidiary SFB AG developed this system technology in the 1990s and has continued to develop it over the last 30 years. The systems are in use in various markets around the world.

Technical data:

Workpiece dimensions:
from D10mm

Throughput:
up to 170 million parts per year / shift

Versions:
Parallel or duplex (over 2 levels)

Powder application:
 Gema / Wagner / Nordson

Area of application:
Worldwide in all markets

Possible workpieces:
– Ferrite rings
– Magnetic rings
– Nanoceramic rings
– Balancing weights
– Parking sensor housings
– Pipe clamps
– Corsetry
– Saw blades
– Handles
– Automotive general
– Bulk goods in general

Production integration:
Integration of automated feeding and dispensing, or inline into existing production

Supply and exhaust air systems

Application examples:

 

Pre-treatment

In pre-treatment systems, steam, also known as mist, is produced. The energy content of the air is very high due to the humidity. Most often, only exhaust air systems are planned. Compensation through fresh air is omitted, and the energy escapes unused through the roof. The negative pressure in the hall is also not compensated.

Solution:
Corrosion-resistant plate heat exchangers or KVS systems with a supply air unit.

 

Powder coating

When the highest qualities are required, the air must also meet these standards. Consistent conditions are essential to keep the process stable. Air that is too dry leads to higher rejection rates.

Solution:
High-pressure humidification and a supply air unit with cooling.

 

Welding shop

In the past, extraction systems with extraction arms were often used. Nowadays, it is evident that these are not used efficiently enough and therefore do not sufficiently protect employees from toxic dust.

Solution:
Integral ventilation concept with source supply air at the workplaces and central extraction with cartridge filters.

 

Painting system

A painting system for drum lids has a very high throughput of surface area and thus solvents. The facility is located in a residential area. The existing system has thermal afterburning (TNV), but this consumes vast amounts of energy.

Solution:
A regenerative thermal oxidation system (RTO) was planned for the new system. The RTO is mostly autothermal and does not require additional fuel. The new system has a 90% reduced energy consumption. Additionally, the existing system was also connected to the new RTO.

Technical data:

Basic components:
– Fans
– Filter systems
– Heating
– Heat recovery
– Humidification
– Cooling / dehumidification
– Exhaust air treatment (e.g., RTO, air scrubbers)

Materials:
– Galvanized steel
– Painted steel
– Stainless steel 1.4307 and 1.4404
– Plastics like PPs

Air volumes:
2,000 – 260,000 m³/h

Temperatures: -20 to 300 °C

Filter systems:
– Coarse dust filter ISO coarse 40% (G3)
– Machine protection filter ISO ePM10 50% (M6)
– Fine filter ISO ePM1 70%
– HEPA filter up to H14
– Air scrubbers

Heating:
– Electric
– Hot water
– Direct/Indirect gas
– Indirect oil
– Thermal oil

Heat recovery:
– Static plate heat exchangers (up to 65% efficiency)
– Rotary heat exchangers (up to 85% efficiency)
– Sorption regenerators (up to 85% efficiency including latent energy/humidity)
– KVS systems (up to 45% efficiency)
– Heat pumps

Humidification:
– High-Pressure humidification with osmosis water
– Ultrasonic atomization
– Steam humidification

Dust extraction systems

Application examples:

 

Metal processing

In a large hall, components are welded and ground. The hall was completely blackened by metal dust that had accumulated over decades, even though decentralized extraction systems were in place. A path for material flow runs through the center.

Solution:
The hall was cleaned, and an intermediate ceiling was installed below the truss. Since then, the air has been extracted at the facades, cleaned with a cartridge filter system, and combined with a supply and exhaust air system that provides fresh air.

 

Wooden windows

The wooden frames and windows are lightly sanded after flooding to break the raised fibers. Typically, the windows were sanded lying on trestles. The dust was not centrally extracted but spread throughout the production area.

Solution 1:
The entire suspension remains in front of an extraction wall. The wall can be moved towards the component. The work is performed ergonomically on the vertical frame. The dust is removed and returned to the room through a HEPA filter.

Solution 2:
The same principle as Solution 1, but the suspension is continuously moved.

 

Welding shop

In the past, extraction systems with extraction arms were often used. Nowadays, it is evident that these are not efficiently used enough and, therefore, do not sufficiently protect employees from toxic dust.

Solution:
Integral ventilation concept with source supply air at the workplaces and central extraction with cartridge filters.

 

Orthopedic technology

In orthopedic technology, a lot of work is done with plaster models and plastics. A lot of dust is generated while working, and solvents are also used.
The new building is planned as a Minergie Plus house, allowing only minimal air volumes.

Solution:
– Recirculating filter system for dust and plastic particles
– Ventilated workstations for handling solvents, including ventilation and activated carbon filters
– Cabinets with integrated extraction and EI90
– Small paint booth for small painting jobs

Technical data:

Basic components:
– Fans
– Filter systems
– Heating
– Heat recovery

Materials:
– Galvanized steel
– Painted steel
– Stainless steel 1.4307 and 1.4404

Air volumes: 2,000 – 80,000 m³/h

Temperatures: Typically room temperature

Filter systems:
– Fine filter ISO ePM1 70%
– HEPA filter up to H14
– Activated carbon

Heating:
– Electric
– Hot Water
– Direct/Indirect Gas
– Indirect oil
– Thermal oil

Heat recovery:
– Static plate heat exchangers (up to 65% efficiency)
– Rotary heat exchangers (up to 85% efficiency)
– Sorption regenerators (up to 85% efficiency, including latent energy/moisture)