Laser cell at WHW Hillebrand as a benchmark for efficient frame cleaning

Cleaning coating frames is a crucial step in surface treatment—and now it's much smarter. Our customer WHW Hillebrand, a leader in the development of coating technologies, has replaced its continuous sandblasting system with an automated laser cleaning system in collaboration with our team from the Production Solutions business segment. The result?

• Low energy/resource consumption
• Low maintenance costs
• Process reliability
• Reproducible quality in line cycles
  

Initial situation

It should be clean –and reproducible

Cleaning coating frames is one of the most important steps in surface coating with cathodic dip coating (CDC). Until now, WHW Hillebrand has relied on a continuous sandblasting system. A reliable method, but costly: high material and energy consumption, as well as extreme wear and tear on the coating frames and the system. That is why Hillebrand planned to convert the continuous sandblasting system to automated laser cleaning – together with us. Simple on paper, but challenging in implementation – the highest requirements applied:

Laser safety: The laser cell had to be completely laserproof and the resulting combustion products had to be safely extracted – integrated into ongoing operations.

Frame variants: The system must be able to process different paint frames with varying cleaning surfaces.

Our solution

For automated laser cleaning at WHW Hillebrand, we developed a customized system that integrates seamlessly into the current process. To achieve this, we drew on our combined expertise in the Production Solutions segment: our special machine construction team in Albersdorf worked hand in hand with our high-precision experts in Ilmenau. Clear responsibilities and short communication channels ensured a streamlined project process – without disrupting ongoing operations.

Technical highlights at a glance

• Laserproof Class 4 cell (with line laser)
• 1 kW laser power, approx. 30 seconds per frame cleaning cycle
• Automatic feeding of workpiece carriers
• Adaptable to a wide variety of coating frames at the touch of a button
• SCIO Automation PLC standard for quick commissioning and expansion
• CE conformity for maximum machine safety

Well thought-out – for maximum process reliability

We deliberately opted for a line laser that can be moved along three axes, as the cleaning surfaces vary depending on the coating frame. The laser can be precisely adjusted to different geometries, which guarantees stable results even with changing shapes. Cleaning is carried out with 1 kW laser power in approx. 30 seconds per frame – in line with the cycle and without wear on the coating frame or the system.

The new laser cell was developed and implemented by us as a Class 4 cell that is completely laserproof. This enabled us to integrate the laser into the customer's overall safety concept and ensure the CE conformity of the laser cell – an area of expertise that we specifically cover within the SCIO Automation Group. For us, machine safety is not an add-on, but part of our end-to-end approach.

Customized instead of off-the-shelf—for greater efficiency

For optimal output, we determined the maximum cleaning speeds and individually adjusted the laser parameters. To ensure reliable cleaning, the coating frames must be securely placed in the laser cell. For this purpose, we use workpiece carriers that fix and transport the frames. Since CAD data was not available for all variants, we recorded the geometries directly on site. This enabled us to tailor the system precisely to the customer's requirements. Whether remotely or directly at the customer's site, we are there where we are needed.

The control system is based on the new SCIO Automation PLC standard. This speeds up commissioning and simplifies future expansions and service calls – a real advantage for ongoing operations.

Conclusion

30-second intervals, lower operating costs, greater sustainability

Laser cleaning at WHW Hillebrand replaces a material-intensive routine with a precise, automated, low-maintenance standard process—with minimal wear, fewer consumables, and consistent quality. The system is also easy to operate—no specially trained personnel are required. The cell fits into the existing material flow and remains flexible for future requirements. This is also confirmed by the customer:

„The system is impressive in every respect. Everything was organized professionally, from machine safety and technical implementation to commissioning. The changeover has significantly reduced our workload and made the process noticeably more efficient. Above all, the people who operate this system are enthusiastic about it.“ 
- R. Koch, Head of Plant and Equipment Technology, WHW Hillebrand

Are you facing similar challenges? We will support you every step of the way—from the initial idea to turnkey implementation.