banner

Technology

Implementation of the unique enamelling technology originating from Slovak know-how has been a breakthrough in the industry and allowed the creation of an exceptionally enduring and quality surface finish.

The technology is based on the application of powder enamels in an electrostatic field, which also ensures the independent position of our manufacturing process in environment protection terms. The effectiveness of this production method and outstanding quality of our products are supported by an ISO 9002 international certificate.

The estap®products manufacturing technology is based on a new physical principle using the effects of Coulomb's Law. This allows the creation of coatings in dry manner in a closed circuit. This method ensures that that the enamelling material which is not applied onto the product surface to create the coating is immediately returned to be recycled. Such use of enamelling material results in nearly 100% consumption without any generation of waste material or environmental and work place pollution. The process is entirely automated and computer-controlled. As a result of its physical nature, this method of enamelled coating application allows the achievement of outstanding quality.

Production process

Mlynica

1. Grinding Plant

Automatic line operating in a controlled mode carries out all the operations needed for the processing of the original material - enamel frit - into enamel powder of the required parameters. The maximum powder grading is 100 microns. Powder processed this way is relatively electrically conductive. Electric Resistivity has to be increased 100 000 times so that we can apply the physical principle of the next phase in enamel coating. Resistivity is increased by means of a surface finish achieved by a special dielectric medium, this creates a "cage" in the molecule layer and the cage keeps the element charged.

Lisovanie

2. Pressing

An automatic press line consists of six basic pieces of equipment:  A feeder takes a plate from the pile of cut–to–size plates and delivers it into press plant 1 which stamps the main tub body (the press is hydraulic, with the power of 1600 tons ). The stamped piece is delivered to press plant 2 which cuts off waste material around the upper part of the tub and shapes the edge bend. Press plant 3 punches in the discharge and overflow outlets and shapes the sub–bend all along the edge. After the de–greasing process the stamped piece goes on to the welding plant which welds on suspension pieces and elements for leg mountings. 

Predúprava

3. Pre-treatment

After stamping the all product surfaces have to be pre-treated before the enamelling process is applied. Pre-treatment include surface de–greasing, rust and other mechanical dirt removal. The entire cleaning process takes place on an automatic line - the last operation of which is drying.

Práškovanie

4. Powder Application

The coating method including the application of enamel powder in an electrostatic field is carried out on an all-automatic line which consists of five coating positions. The first two positions create the basic enamel coating and the remaining three positions create the enamel cover coating. The product is transported on an overhead conveyer belt, passing through all the positions. The enamel powder coatings form on the product surface as a result of the Coulomb process. These forces are subtle, disappear over time and get weaker with decreasing element charge. The firm adhesion of the coating to the back plate is achieved by means of a burning process at about 800 degrees Celsius; this is done in a conveyer tunnel kiln. 

Vypaľovanie

5. Burning Process

The enamel powder coated product is transported from overhead coating conveyor to overhead kiln conveyor and is transported to tunnel kiln conveyer. Here, in the main fire zone where a pre-determined burning mode ensures that the basic enamel firmly adheres to surface of the product and the enamel cover coating is formed. After the temperature of products cools, these are checked and packaged right on the conveyor.

Kontrola

6. Kontrola

Prevesením výrobku, na ktorom sú vrstvy prášku smaltu z nanášacieho podvesného dopravníka na podvesný dopravník vypaľovacej pece, je tento unášaný do žiarového pásma priebežnej tunelovej pece.

Tu v stanovenom vypaľovacom režime prebehnú reakcie, ktoré sprostredkujú pevné spojenie základného smaltu s povrchom výrobku a vytvorenie celistvej vrstvy takzvaného krycieho smaltu. Po postupnom vychladení výrobkov sú tieto priamo na dopravníku kontrolované a balené.

 

Why the Estap tubs
are unique?

  • Quattro enamel anti adhesive coating
  • environment-friendly manufacturing process
  • excellent lifetime up to 30 years
  • exceptional sanitary surface
  • enamel three times more flexible and resistant
  • unique surface finish
  • maximum recyclable capacity
  • perfectly smooth surface
  • competitive prices
  • top quality
  • simple installation
  • high polish