• Higher quality: thickness of 50 microns
  • Better visual appearance: Excellent uniform finishing on the entire surface.
  • Greater durability: The Best anti-corrosion system on the market guaranteed anti-perforation. 
  • Greener process

What does our KTL installation include?  

  • It is the largest e-coat plant in Europe, for immersion due to the capacity of the tanks, with a surface area of 10.000 m2. 
  • Each of the 10 tanks used in the process has a capacity of 210 m3 (210.000 litres).
  • It has been conducted by the best national and international suppliers in each of the areas to be developed.
  • At Lecitrailer, we will paint our own products and external parts: chassis, bodywork, trucks...…
    • Maximum size of the part is  14 x 2,6 x 2,8m
    • Maximum weight of the part is 5 Tn

Summary of stages

  1. Shot Blasting.
  2. Degreasing - alkaline spray.
  3. Degreasing - alkaline immersion.
  4. Rinsing.
  5. Rinsing.
  6. Nanotechnological conversion (10-12 nanos) - zirconium salts.
  7. Rinsing.
  8. Rinsing.
  9. KTL - deposition of Epoxy Primer (40-50 microns).
  10. Rinsing.
  11. Rinsing.
  12. Pre-heating 80ºC.
  13. Polymerisation-oven-180º C 40 mins.
  14. Cooling.
Resumen de etapas

What does our KTL facility involve, technically speaking? 

It involves the installation of the most modern cataphoretic coating system on the market: KTL with nanotechnological conversion. This is the technology used in automotive industry which has the highest quality standards.  
KTL applies a layer of Epoxy primer through complete immersion and then passing an electrical current (Electrophoretic deposition).  
The nanotechnological conversion will ensure that the KTL layer is even, with the same thickness of the layer over its entire surface and reaching all the nooks and crannies of the part. 
KLT

The process: 

Arrival of the part:  2 platforms, our chassis arrive on skid at ground level and the outer parts (bodywork, cranes...) via air freight.  
  • Not everyone shot blasts before the KTL process, but we do, and this is a significant advantage of ours. 
  • In addition, this area represents improvements over our previous shot blasting system due to:
    • The greater power of the new shot blasting machine (24 turbines instead of the 16 it had previously). 
    • It allows us to put parts in which are both hanging and at ground level.
    • Greater versatility, due to the different geometries of the parts.  
    • Larger size and capacity up to 5000Kg (the bodywork also fits). 
  • Shot blasting output area - al fondo, at the back, the shot tumbler: 
    • Rotating air throughout full 360º, which facilitates the elimination of all shot debris. 
    • Its geometry makes it versatile for all the model type we manufacture. 
    • Once all the shot debris has been eliminated in the rotating tumbler, the part reaches the programmed carts in the tanks using the lifting platform (to the left in yellow) and from there, the part will be successively entered into the 10 tanks. 
Granalla automática
  • It is the largest KTL plant in Europe, in terms of immersion due to the capacity of the tanks: each of the 10 tanks used in the process has a capacity of 210 m3. The length of the tanks is 14.m
  • It is an extremely clean and well-prepared process for immersion and forced electrical current which will ensure that the paint reaches all nooks and crannies.  
  • The treatment time passed between the first and last tank is 30 minutes.  
    • Every 15 minutes a treated part comes out. Cycle time: 15 mins. 
    • The tank installation contains two parts at the same time, and tank 6 is the interchange point.  
  • Through the cycle, variables such as temperature, PH balance and water conductivity are measured and controlled from the control room to 100% guarantee optimal quality during the process. 
  • The content of the tanks is constantly stirred to guarantee the highest quality of the system  
  • Tank 1: Degreasing by alkaline spray at 50ºC.
    • To clean the shot blasted part. 
    • It contains the only spray treatment as the rest of the treatments are via immersion.
    • Very high pressure spray with osmotic water and alkaline detergents (soap).  
  • Tank 2: Degreasing via alkaline immersion at 50ºC.
  • Tank 3: 1st rinse by immersion.
    • With purified osmotic water.
  • Tank 4: 2nd rinse by immersion.
    • With purified osmotic and demineralised water.
  • Tank 5: Nanotechnological conversion.
    • Surface preparation with zirconium salts to ensure optimal adhesion of the paint which will be applied in tank 8.  
    • Performed at  40ºC.
    • The thickness of the layer of zirconium salts is nanotechnology, between 10 and 12 nanos.
  • Tank 6: 3rd rinse by immersion, elimination of impurities.
    • Our facility is designed in such a way that, in tank 6, the interchange of the part between the 2 programmed carts is also carried out.
  • Tank 7: Rinse by immersion with very pure demineralised water achieved with double osmosis. 
  • Tank 8: Electrophoretic deposition - cataphoresis KTL.
    • With the application of a high electrical current after immersion of the part in this tank, a difference in strength is caused which will make the paint adhere evenly to the part all over its surface, reaching every nook and cranny.  
    • Ecological treatment: Water based paint with 2 components.
    • Grey tone- as proof of our self-commitment, so that when it is later painted, the gaps in the painting will be highlighted. If we painted black on black, like other competitors, the defects would be more easily hidden.  
    • Higher quality: The thickness of the layer of paint is 50 microns (compared to the 15-20 previously applied) which has been achieved:
      • With longer immersion time.
      • With a high current - 300 volts, 1200 amperes
  • Tanks 9 y 10:  Cataphoresis rinsing
    • Following the ecological principle of this facility, the last two tanks rinse the excess paint resulting from tank 8 for maximum recovery (99%) of both pain and excess water to be reused later. 
Cubas 
Cubas
 
Cubas
 
Cubas
  • Pre-heating  80º
  • Heating - polymerisation - 180º 40 mins approx for optimal results and better adhesion.  
  • Cooling.
Secado Horno

Fork of parts destined to paint depending on

  • Chassis which go directly to the chassis paint line. 
  • External part which go to auxiliary cabins located in this plant.