Part I of Solving Our Customer’s Challenges: The Walls Are Closing In
Going beyond our technologically advanced components and space saving design, a large part of our job at IntelliFinishing is working with our customers to solve their problems and challenges. There are usually a few key hurdles that lead a customer to consider purchasing a system or renovating their existing setup. As part of a four part series, we will look at the specific challenges one of our recent customers faced, and the solutions provided by IntelliFinishing.
The first concern for our customer was how they were going to replace their existing manual paint shop with an automated, state-of-the-art IntelliFinishing system in the same space, which only measured 74 feet across and 55 feet deep.
IntelliFinishing’s solution to this challenge was to make use of our unique conveyor design that allows our product carriers to flow forwards and backwards, independent of other carriers in the system. This allowed us to “dead head” or “spur” into areas like an inspection platform and a washer to reduce space. In the curing oven we used our variable speed drives to speed up or slow down dwell times based on the part recipe. This, along with in-depth part tracking, allowed our curing oven to be much smaller in size, while allowing the wide range of flexibility required by the variety of parts being coated. Finally, since our system is truly decoupled, we could incorporate short motor breaks for inspection and masking areas without affecting the effective line speed throughout the rest of the system.
As a result of our innovative equipment and controls, IntelliFinishing was able to successfully design a system that met all of the customer’s goals while not exceeding the 4,000 square foot area of the outdated manual system. Find out how our use of shuttles and lowerators can reduce your system footprint while maintaining or exceeding your expectations for performance and flexibility!
Read Part II
Read Part III
Read Part IV
A Plan for Every Part©
Ever wish you had a different finishing line for every type of part you have to paint or powder coat? Large heavy parts take more time to process than small thin ones. Some parts require additional masking and others don’t. Different chemistry is required for different types of metals… the list seems to be endless.
IntelliFinishing has presented to a variety of audiences recently and manufacturers are impressed with the “Plan for Every Part©” technology. Each item you process gets the best finish available, just like the system was built specifically for that part.
Unlike traditional finishing systems where the system is built for your longest or heaviest part, which results in over-baking of other parts; the IntelliFinishing finishing system provides capabilities that are unmatched in the finishing industry.
With conveyors that move load bars of parts at varying speeds which are based on the parts’ unique size and material, an IntelliFinishing system offers capabilities in ONE LINE that would take MULTIPLE LINES for traditional systems. Customers have been amazed at what can be accomplished with layouts that are not limited by a one-way, one-speed conveyor.
The IntelliFinishing system is not for everyone.
- Do you finish a variety of sizes of parts?
- Do you finish parts that are made from different materials?
- Do your processes for finishing ever change?
If you answered YES to any of the above questions, then you may want to see how an IntelliFinishing system is rocking the world of finishing. Contact us at firstname.lastname@example.org.
The capabilities of the IntelliFinishing turnkey system are numerous, as are the features this system has. Having the ability to move parts in individual areas forward and backward, as well as moving at different speeds, without affecting the rest of your line has been a key element in understanding the savings benefit of the IntelliFinishing System. Not only does this save in floor space usage, it also saves in energy costs, and chemical and water usage.
Imagine if you could only drive your vehicle in the forward direction, at one speed which is based on the vehicle driving in front of you…this scenario limits your abilities to get where you want to go. So why have a finishing system with that same limitation? Give us a call at 888-886-6363 or email us at email@example.com. We’ll take the time to talk to you about your needs, answer any questions you have about the IntelliFinishing System and design a system that meets and exceeds your expectations.
Part I: Changing the “Game”! – Improving Paint System Design
IntelliFinishing has had a great start in the introduction of our new industrial paint system. We’ve had a fantastic response from numerous companies that do industrial coating. I think our favorite comment so far has been, “Wow! Seriously,…I can do that?” It was a great “ah-ha” moment.
IntelliFinishing is really changing how people think about finishing systems. We know it is hard to pull your mind from the way a finishing system has always been; stationary, single speed, single direction, take it or leave it type systems. Once you understand the IntelliFinishing system, it will shatter your preconceived notions and known limitations of what a paint finishing system has been.
Here are some highlights from the Paint System Designs we’ve created:
- Opened up three bays of floor space, that’s 1200 sq. ft., utilizing our advanced conveyor and system technology, while also adding additional process equipment.
- Fit an entire Powder Coating system; load/unload area, 3-stage washer, dry-off oven, cooling areas, powder booth, cure oven and bias banking into a 2,540 sq. ft. area to process a 19’ long part.
- Designed a complete liquid and powder system as one singular system; giving the customer ultimate flexibility to run their ever changing parts. When their customer demand needs more liquid painted, it wasn’t a problem; and if that afternoon they needed to run parts through powder for another customer, it could all be done on the same system.
We have had a fantastic time developing these paint system designs and implementing them for our customers. It has allowed us to share our knowledge and excitement about the IntelliFinishing system, as well as expand our technology to meet the ever changing needs industrial finishing companies face, and trust us; there have been some interesting challenges! The solutions we have developed due to the flexibility of our system have brought about a number of “ah-ha” moments from our customers as their conventional understanding of conveyors and finishing systems is quite suddenly thrown out the window.
Give us a call at 888-886-6363 or email us at firstname.lastname@example.org and let us know about your challenge!
Engineering & Sales Coordinator
A “Chainless” Power & Free Conveyor?
The IntelliFinishing conveyor is a bolted together floor supported system with friction driven trolleys on a rotating tube instead of a chain to drive the system. Due to the bolt together construction, this conveyor can be easily modified and moved and can be installed in half the time of conventional conveyor systems. We offer a variety of conveyor models with the ability to handle different weight categories which enables us to further customize a system to fit your specific process needs
With our Chainless Power & Free there is no maintenance or mess of keeping the conveyor constantly lubed, additionally there is no mess or contamination of lubes, oils, or grit falling onto the parts processed. All of the moving components in the conveyor system are lubricated for life.
Each conveyor section has a separate motor which allows individual sections of the conveyor to speed up a part in a process area or slow a part down based on the part recipe. The separate motors also turn off and on the individual conveyor sections when there is a part present making this system more energy efficient because the full system isn’t always running, only the process areas being used at the given time. Additionally, the Chainless Power & Free conveyor has a much quieter operation due to no metal on metal noise.
Capabilities of the Conveyor (partial list):
- Change processes or destinations of products with immediate system response
- Set up in-line speed changes
- Run trolleys both forward and backwards
- Stop a carrier for processing without stopping the entire line or holding up production
- Easily incorporate vertical lifts and shuttles to move parts to another line without unloading
- Negotiate inclines and declines
- Accumulate loads in line
- Have both driven and non-driven lines on the same system
- Dip the conveyor into tanks
- Run the conveyor through Dry-off and Cure Ovens up to 450 degrees
- Highly configurable and modular