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


 

Pretreatment Systems


During the pretreatment process, water vapour (mist) is generated, resulting in air with a high moisture and energy content. Many installations rely solely on exhaust air systems, meaning that conditioned air is discharged unused while replacement air is drawn into the building. This not only wastes energy but also creates unwanted negative pressure within the production hall.

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

 

Powder coating Systems


High-quality powder coating systems require precisely controlled ambient conditions to ensure stable production processes and consistent coating quality. Air that is too dry can increase reject rates and negatively affect the coating process.

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

 

Welding shops


Traditional extraction systems using extraction arms are often insufficient because they are not consistently positioned close to the emission source. As a result, employees may still be exposed to hazardous welding fumes and fine dust.

Solution:
An integrated ventilation concept with source air supply at each workstation and central extraction using high-performance cartridge filters.

 

Liquid Paint Systems


A liquid paint system for drum lids generates very high solvent loads due to its large coated surface area. The production facility is located in a residential area. Although the existing installation was equipped with a thermal oxidizer (TNV), its energy consumption was extremely high.

Solution:
A Regenerative Thermal Oxidizer (RTO) was implemented for the new installation. The RTO operates largely autothermally and requires little or no additional fuel. Compared to the previous solution, energy consumption was reduced by approximately 90%. The existing coating system was also connected to the new RTO, further increasing overall efficiency.

Technical data

Core components
– Fans
– Filtraiton systems
– Heating
– Heat recovery
– Humidification
– Cooling and dehumidification
– Exhaust air treatment (e.g. RTO systems and air scrubbers)

Materials
– Galvanized steel
– Painted steel
– Stainless steel 1.4307 / 1.4404
– Plastics such as PPs

Airflow:
2,000–260,000 m³/h

Operating Temperature: -20 to 300 °C

Filtration 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 Media
– Electricity
– Hot water
– Direct and 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 heat recorvery systems (up to 45% efficiency)
– Heat pumps

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

Dust extraction systems

Application examples:


 

Metal processing


In a large production hall, metal components are welded and ground. Although decentralized extraction systems were installed, fine metal dust had accumulated throughout the building over many years, blackening large areas of the hall. A central material flow route also had to remain unobstructed.

Solution:
The production hall was thoroughly cleaned, and an intermediate ceiling was installed below the roof structure. Air is now extracted at the facades, filtered through a high-performance cartridge filter system and combined with a supply and exhaust air system that continuously provides fresh air.

 

Wooden windows


After flood coating, wooden frames and windows are lightly sanded to remove the raised wood fibres. Traditionally, the workpieces were sanded horizontally on trestles, allowing dust to spread throughout the production area.

Solution 1:
The complete suspension remains positioned in front of a movable extraction wall that can be adjusted to the workpiece. This allows ergonomic processing of the vertically suspended frames while the sanding dust is extracted and returned to the workplace through a HEPA filtration system.

Solution 2:
The same principle as Solution 1, with the suspension moving continuously through the workstation.

 

Welding shop


Traditional welding shops often relied on extraction arms. In practice, however, these systems are frequently not positioned correctly and therefore cannot provide sufficient protection against hazardous welding fumes and fine dust.

Solution:
An integrated ventilation concept with source air supply at each workstation and central extraction using high-performance cartridge filters.

 

Orthopaedic technology


Orthopaedic workshops process large quantities of plaster models and plastics, generating significant amounts of dust while also using solvents during manufacturing. In this project, the new production facility was designed as a Minergie-P building with very limited permitted air volumes.

Solution:
– Recirculating filter system for plaster and plastic dust
– Ventilated workstations with activated carbon filtration for solvent handling
– Storage cabinets with integrated extraction and EI90 fire protection
– Compact paint booth for small coating applications

Technical data

Core components
– Fans
– Filtration systems
– Heating
– Heat recovery

Materials
– Galvanized steel
– Painted steel
– Stainless steel 1.4307 / 1.4404

Airflow: 2,000–80,000 m³/h

Operating Temperature: Typically ambient room temperature

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

Heating Media
– Electricity
– Hot Water
– Direct and 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)