12 Days of Christmas IntelliFinishing Style

View the 12 Days of Christmas IntelliFinishing Style VideoThere’s not a better time of year to think about a new complete finishing system. Peek through the pages of the 12 Days of Christmas IntelliFinishing style to see all the benefits and advantages of choosing our alternative to power and free system.

From the first day of Christmas to the 12th, we have something special for you.  View the video at http://intellifinishing.com/12days.html

Tour an Active Construction Site

Kevin Howe, IntelliFinishing Project Manager

IFconstruction

Kevin just finished the setup on IntelliFinishing’s latest project installation. During the construction process he took us on a brief tour. It was an active construction site so the system wasn’t running yet. View the tour video >>

The IntelliFinishing system starts with a lift, which is basically an elevator-style, drop section. The orange pieces of the conveyor will come down to a lower height making it more ergonomic for connecting the parts to the carrier. Then it will rise back up after the part information is loaded and send the carrier into the system.

The control stations will have a touch screen monitor that will display different part information.

The uninstalled load bars are the mechanical pieces that support picture frame style hangers that will in turn support the customer parts. The metal trolleys are the load trolleys that support the weight of the entire piece. The rubber wheels on the top contact our spinning tube and provide the propulsion for the conveyer system. It is a friction setup with a spring tension pressing against the tube. The IntelliFinishing system is unique as it goes forward and reverse directions. This typical configuration is capable of supporting 3,000 pounds, including the weight of the load bar.

From the elevator-style lift section we proceed downstream towards a manual wash booth area. In this instance, we’re interfacing to a customer provided wash booth. We are going to control the doors that will slide open and closed pneumatically. Internally the wash booth will be similar to a manual car wash bay. The operator will select a cleaner rinse, a phosphate rinse and a sealer to keep the parts from flash rusting.

From the wash bay we head to the small drip zone. Currently this is a manual pull through section, which the customer requested for Phase 1. In Phase 2 we will add an automated wash parallel to this section. At that time most of the parts will go through the automated wash so in the future, less volume will run on the pull through section.

Parts will then be pulled to the first motorized section after the wash booth to air blow off. The air blow off is also similar to a car wash system with nozzles and large, electrically powered air blowers. The nozzles will be directed at the parts to dry off any of the residual water.

After the blow off area is a dry off oven. This oven is a little smaller, holding one carrier at a time. The oven is used to help boil off any leftover residual water that was not taken care of in the air blow off stage. It also helps to preheat the part, getting it ready prior to powder coating.

We head out of the dry off oven and around the corner to the powder coat booth. This is a manually applied powder station at this time. They will have several operators, one on each side, applying the powder coat to the parts. Monitors will also let the operators know what color they are supposed to be painting and what is coming up next.

The last station is the cure oven. This is a 450° powder oven. It has 3 motor stations and will be able to hold 3-4 carriers worth of parts at a time. When the units are finished curing, they come out to a several storage areas to give them time to cool.

Since our system is an oval it then brings us back to the beginning. This is the backside of the lift elevator section we saw at the start.

View the construction tour video >>

Ask Joe Powder

Another Midwest Coatings Seminar has come and gone. If you missed the opportunity to join us this year, here’s a snippet or two on what you missed!

  • Did you know that Epoxies tend to yellow with overbake, but contain good undercure properties
  • Hybrids offer better color stability than Epoxies

Does your curing oven maintain the same temperature throughout your Production day? How often do you need to test the cure? How do you test the cure?

These are just a few of the questions that our friend and colleague Kevin Biller aka “Joe Powder” answered in detail at the Midwest Coatings Seminar 2014. Kevin was one of the guest speakers for our event this year, and is the President of Powder Coating Research Group.

His presentation began with the trouble we have working with Galvanized material. He explained the world of differences between Electrogalvanized vs. Hot Dipped.  He discussed how to minimize gassing with preheating and spraying warm and moved on to the important processes that should be in place to achieve an adequate cure, with the first step in the process being to consult the Product Data Sheets for important details for the coatings process. He provided excellent information on troubleshooting curing issues:

  • Heavier than normal parts – low metal temp
  • High oven loads
  • Increased line speed not allowing parts to get up to temperature to cure
  • Wrong Powder Coating used in process (check Product Data Sheets!)
  • Overcure – line stoppages or empty lines
  • Chemistry issues

Have you ever seen “orange peel” or cratering on your powder parts? Craters can come from many sources in your paint shop. Do you have any of the following located in or near your paint lines?

  • Oil
  • Grease, lubes
  • WD-40
  • Silicone grease, sealants
  • Other powders
  • Hygiene products – lotions, creams, etc.

Crater contaminates normally occur BEFORE the powder is baked. Introducing a few key procedures can reduce and prevent these issues.

Kevin provided various insights on the recoating of parts and the importance of recoating completely. He also included pre-treatment practices and testing for corrosion resistance. >> Kevin’s column Ask Joe Powder is featured in Powder Coated Tough Magazine

Would you like to subscribe to receive information about upcoming seminars? Follow this link intellifinishing.com/mcs.

Midwest Coating Seminar 2014 Review

Midwest Coating Seminar 2014

Hard Rock Hotel and Casino

August 21, 2014

IntelliFinishing hosted our annual Midwest Coating Seminar in Tulsa, Oklahoma at the Hard Rock Hotel and Casino. We had a great time (didn’t lose much money) and learned a great deal from Kevin Biller of The Powder Coating Research Group and Mike Dilday of Fanuc America Corporation. Many companies from a variety of industries including:  aerospace, oil and gas, custom coaters, custom fabricators, construction equipment and ag equipment manufacturers, were present.

The day started with an introduction by IntelliFinishing’s vice president, Doug Olipant, who explained the purpose of the annual Midwest Coating Seminar is to bring in subject matter experts to the Midwest. Doug said, “We travel to trade shows and conferences every year and recognize that our own manufacturing region of the country does not have many of these opportunities to learn about the latest in the powder coating and liquid coating industry. We bring them in to share their knowledge with our staff and others.”

With all of the recent innovations with powder coating and robots used in the finishing industry, we provided a 10-minute introduction to the flexibility that an IntelliFinishing system has to offer. Process changes and product changes are easily adapted with our unique friction conveyor (power and free alternative) and smart controls with recipes for your variety of parts.

A video from an active powder coating system job site was also provided, www.intellifinishing.com/construction. Kevin Howe, IntelliFinishing’s project manager, gave a brief tour of the progress and discussed how the customer was implementing the project in phases. The first phase features some manual pull sections, with most of the system automated. A second phase will later be implemented with more automation and the addition of an automated wash system as their production increases. Since our conveyor has no chain, additions and modifications can be accomplished without affecting production.

Even though Doug warned the audience they would be stuck for hours listening to the commercial, like they do in the timeshare industry, Kevin Biller, from The Powder Coating Research Group, was introduced after the short 15-minute introduction.

KevinBillerKevin Biller’s presentations, “Introduction to Powder Coating Technology” and “Recent Innovations in Powder Coatings Technology”, followed Kevin’s philosophy of formulating – Simplicity + Quality. Kevin’s presentations were easy to understand (even if your last chemistry class was in high school and they only thing you learned there was how excited your chemistry teacher became when you figured out alcohol was flammable).

We look forward to hosting another seminar and if you would like to receive notification of our next one,  click on SUBSCRIBE.

“Introduction to Powder Coating”

In the “Introduction to Powder Coating Technology”, Kevin provided an exciting announcement about a new company, Matrix Powder Coatings, formed in partnership with Ernie Green Industries (EGI). Matrix Powder Coatings produces and supplies unique custom powder coating technology. Matrix Powder Coatings is a game changing, revolutionary, high tech powder coating manufacturer and supplier specializing in low temperature and UV curable powders for non-traditional substrates, high heat resistant coatings, dead mattes and powders for extreme environments.  (Link to press release or visit July/August edition of Powder Coated Tough )

During the “Introduction to Powder Coating Technology”, Kevin explained powder coating’s value proposition as the following: neat, cleaner for the environment, energy saving, high quality, efficient and economical. He then went on to explain the features and application uses of the powder coating technologies, including:

  • Epoxies – used as functional and primers
  • Epoxy Polyester (Hybrid) – used for interior and general purpose applications, e.g. office furniture
  • Polyester – used in the architectural industry and for general purpose
  • Polyester Urethane – used for its higher toughness, e.g. lawn mowers
  • Acrylic-Diacid – used in the automotive industry
  • Acrylic Epoxy – used by appliance manufacturers
  • Acrylic Urethane - used by appliance manufacturers and architectural industry
  • Silicone – used for exhaust parts and grills
  • Fluoropolymer – used in the architectural industry

The main thing about working with powder coating formulations is to avoid band-aids and to start with the right stuff based on your product’s requirements.

“Recent Innovations in Powder Coatings Technology”

Kevin opened this presentation with the powder coatings shortcomings like

  • Relatively high bake temperature (350 to 400ºF)
  • Need substrate conductivity (electrostatic application)
  • Difficult color change
  • Film thickness

Kevin then went on to discuss the emerging technologies including:

  • Non-Chrome Alternatives using rare earth based primers, Cr+6, Cr+3, Zirconium
  • Smart Coatings – coatings that respond to environmental stimuli and change the nature of coating like superhydrophopic, thermal chronic, photocatalytic self-cleaning, anti microbial
  • In-Mold Coating – developed in 1990’s for sinktops/shower stalls, rejuvenated in 2010
  • Low Temperature Cure- reducing oven temperatures by as much as 35%

The low temperature cure discussion included information about the latest in UV cure as well. Powder is applied electrostatically, melted at 212-248ºF, then cured with UV. An example was provided of the use of a robot to provide the UV cure. Members of the audience were excited about this development and could see the impact this innovation could have on manufacturing and assembly of their products.

Powder on plastic or other non-conductive substrates was also explained and its potential for revolutionizing the industry.

After lunch, Mike Dilday from Fanuc America Corporation demonstrated and presented the use of robots in the powder coating and liquid paint systems. During lunch, he shared videos of robots used in paint systems.

“Robotic Paint and Powder Coating”

FANUC-robot

Click to see video of robot

Robots have traditionally been used on liquid paint lines and recently, the number of robots used in powder coating is growing. Robot usage continues to increase due to demand for better quality, more flexibility and quicker return on investment due to decreases in robot prices. Robots also improve throughput, emissions compliance and are ergonomic.

Mike Dilday reviewed when to use robots.

  • High Articulation Requirements
  • High Material Cost – Minimize Waste
  • Two Shift Operations
  • Multiple Paint/Powder Settings for Control
  • Smart Reciprocator Alternative
  • Labor reallocation/high turnover
  • Safety and ergonomics

    • Minimize carpal tunnel syndrome occurrence
    • Remove sprayer from hazardous tasks

Another consideration of robots is as a reciprocator replacement. The benefits of a robot over a reciprocator include the following:

  • Line Tracking
  • Eliminates Tiger Stripping
  • Extra Articulation Capacity
    • Leading and Following Edge
    • Contour capability
  • Precise Triggering Capability
  • Material Reduction 

Implementing robots can provide a high return on investment due to labor savings, material savings, reduced warranty claims, increased production and throughput. Customer requirements for implementing a robot in your paint system are one dedicated robot operator per shift, knowledge of managing the liquid or powder spray system (robot technical knowledge can be taught) and consistent part presentation (the most important aspect).

 

 

Educational Seminar for Manufacturers

MCS-email-banner

The Midwest Coating Seminar is an educational seminar for manufacturers, custom coaters and fabricators. It will be held at Tulsa’s Hard Rock Casino on Thursday, August 21, 2014. This seminar will be helpful for companies who have liquid or powder paint lines.

Powder Coating History and Future will be presented by Kevin Biller of Powder Coating Research Group, Technical Editor of Powder Coated Tough magazine and author of monthly column, “Ask Joe Powder”.

Powder coating technology will be introduced from a historical, market and technical perspective. Chemical types will be explained and positioned as to how their performance ranks per the general requirements of UV durability, chemical resistance and film mechanical properties.

The second half of the presentation will take you on a journey of where powder coating technology is emerging. Particular focus will be on how the evolution of non-traditional substrates are spawning new chemistries and processes to deliver powder coatings as a high performance finish. An overview of low temperature cure, UV cure and corresponding processes will be analyzed including how they fit into novel manufacturing techniques.

Following lunch (provided by your host, IntelliFinishing), Mike Dilday of FANUC America Corporation will present The Benefits of Robotic Paint and Powder Coating. This session will focus on the various types of robots typically used for paint and powder coating, and the benefits associated with using flexible robotic automation.  We will discuss why certain robots are used for different types of applications and how material savings, higher transfer efficiencies, labor savings, and warranty reductions can all lead to a healthy return on investment.  Case studies and application videos will also be presented.

The day will be wrapped up with an informal session led by “Ask Joe Powder”. Not everything we endeavor works to plan so Joe Powder will be available to field your questions, comments and perplexities regarding powder coating technology. Joe writes a column that has appeared in Finishing Today, Metal Finishing, IndiaPowderCoatings, Asia Paint and Coatings Journal and Powder Coated Tough publications. Joe will do his best to point you in the right direction to solve your coating issues. Bring all your queries and challenges for Joe.

August 6, 2014 is the registration deadline and you may register for the seminar, which is sponsored by IntelliFinishing by visiting www.intellifinishing.com/mcs or call 785-309-0356, ext 179 or ext 197.

IntelliFinishing is a provider of finishing systems to local equipment manufacturers and to companies like Raytheon and Caterpillar. IntelliFinishing is changing the mindset of finishing with controls and conveyance that move parts forward and backward, provides smart tracking, and simplifies the management of part variety with a recipe-based system.

Page 1 of 512345»