Complete Paint System Open House – Albers Finishing & Solutions

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Interested in learning more about IntelliFinishing’s powder coating or liquid paint systems? Join us on March 24, 2016 and see our newest installation in full production mode at Albers Finishing & Solutions in Cheney, KS. Our IntelliFinishing team will be available all to day to answer questions and highlight all of the features we offer in our complete finishing systems.

Albers open house

Albers Finishing & Solutions, located in Cheney, Kansas, would like to announce they will host an open house at their facility located at
38628 West 15th St. South
Cheney Kansas 
10am to 3pm on March 24, 2016
RSVP

Cheney is located 30 miles west of Wichita on Highway 400.

Review a simulation and to sign up, visit www.intellifinishing.com/albers.

Albers Finishing & Solutions provides liquid paint services to regional and national customers. The highly automated paint line has a part window of 2’W x 4’H x 8’L and can handle up to 500lbs of weight on each load bar.  Albers Finishing & Solutions was created in response to a local manufacturer who had a need to provide a finished product but didn’t want to stray from their core business by adding paint inside their operation. Albers Finishing & Solutions took on the challenge of solving the client’s needs while at the same time building a versatile facility that can serve many industries.
Currently, the liquid paint line is capable of painting 2,000 to 3,000 parts per day and features an automated conveyor that moves load bars forward and reverse or even stops them independently of every other load bar in the system, a three-stage wash, dry off oven, two paint booths equipped with Fanuc robots applying liquid primer and paint via automated paint mix equipment, a dual-lane energy-efficient cure oven and a load-assist lifter.

The line was designed and installed by IntelliFinishing based out of Salina, KS. Woody Miller, IntelliFinishing’s project manager states, “This paint system offers some of the best and newest advances in the industry. With advanced automation and controls, energy efficiencies, and floor space savings, the cost to paint each part is less than other systems. This is a very high-end system, located here in Cheney. Other manufacturers are struggling with their “monument” systems and would love to have a system like this.”

IntelliFinishing teamed up with Downey Consulting, a local company in designing the following for the system: load-assist lifter, carriers, loadbars, hangars and a rotator mechanism in each paint booth. The parts are hung on a custom loadbar with a spinner wheel, and spun utilizing the air operated (intrinsically safe) rotator.  All of this is controlled by the PLC.  The wireless lifter mechanism is capable of removing the loadbar from the carrier fully loaded with parts, placing finished product on racks, or changing loadbars for a different type/style of part.  This allows the ultimate in flexibility of the system.

Bret Albers of Albers Finishing & Solutions states, “Albers Finishing & Solutions will be launching with some of the latest technology available in the paint industry.  The IntelliFinishing system provides the ultimate in flexibility, automation and energy saving features.  Being fully automated and robotic allows us to provide clients with a consistent product each and every time. On top of that IntelliFinishing has the best support team in the business.  Their design team, installation crew, programming staff and marketing are second to none.”

“In addition to superior quality and consistency, companies choosing Albers Finishing & Solutions will also experience the ultimate in customer service.  Our goal is to be your partner, not just another contractor.  We understand how important turnaround times, communication on the status of your product, quality control, and proper packing are to the success of your business so come by and check us out to see what we can do for you,” explains Bret Albers.

Plans to expand the business include powder coating and anodizing processes.

The owners of Albers Finishing & Solutions have been involved in other businesses including: Art’s & Mary’s Tater Chips, Leadfoot Express Transport and D’Mario’s Pizza Outlets.

 

Old Technology. New Technology.

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New vs Old
Why use 40-year-old technology in your new paint system?

Why Use Old Technology on a New Finishing System?

Are you still using old technology when painting parts? We invite you to take a look at some of the new technology that is out there and apply the benefits it can bring to your particular situation!

Visit www.intellifinishing.com where you can take a look at what new technology has to offer when you require a turnkey liquid paint system, powder coating system or an automated paint system.

Alternative to Power and Free Conveyor

IntelliFinishing Complete Paint Systems are an exciting alternative to power and free systems.

We want to share with you a few of the advantages you can expect when replacing your traditional power and free or monorail systems with the newest technology for industrial paint system replacement.

Floor Space Savings

One of the benefits that our customers and potential customers talk a lot about is the amount of floor space that can be saved. In some cases, as much as 43%. By eliminating bulb turns, shuttles used in new technology can decrease your footprint exponentially, which can add up to thousands of dollars of savings. If you are processing large parts, our shuttle demo should move to the top of your “to-do list” right now.

No Chain

picture of IntelliFinishing conveyor
Conveyor is propelled with spinning tube – no chain

Our industrial paint systems are “chain free”. (They are also awesome). No chain means no extra space is needed for the return chain as in a power & free system. Awesome because, your footprint just got smaller again!

On this same note, no chain means the ability to reverse – AND – no messy oil dripping on your parts or collecting dust.

Virtually Noiseless

Another cost-saving benefit, especially for large manufacturing companies, could come in the form of dollars spent supplying employees with hearing protection. One of our customer’s finishing systems is less than 75db, which resulted in the removal of employees from a hearing conservation program. Being a “no chain” system means no dogs or buffer zones, and that equates to: no metal carriers crashing into each other, further reducing noise.

Variable Speeds

A turnkey powder coating system provided by IntelliFinishing makes part sway a thing of the past! New technology with variable frequency drives (VFD) controls the conveyor’s motion, and Smart Controls allow for variable speeds and independently controlled zones for different recipes. New technology gives you the ability to monitor and track parts at ANY point in the system. (Seriously, you need to take a look at one of our demos of an automated powder coating system).

Layout Options

Our switches provide layout options just like the old technology, but additionally, a switch in a complete finishing system provided by IntelliFinishing can be used to deadhead, providing even more layout processing options. (Have you picked up the phone to schedule a demo yet?)

Energy Savings

With the new technology used in an IntelliFinishing complete finishing system, the conveyor runs only when the carrier is present. Additionally, the supporting process equipment, like a washer, also only runs when a part is present.

Modular and Expandable

We all intend for our business to grow. Will your “old” technology grow with you? Our “new” technology will. The modular design of an IntelliFinishing system allows for easily expandable floor plan. As your company grows, your production levels change. Our turnkey finishing systems grow with you and additional processes or applications can be installed quickly. Call us.

Part III: The Lights are On, But No One is Home

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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 third goal for our customer was to reduce energy consumption and eliminate waste as much as possible. This makes sense, as energy rates continue to rise and the emphasis on lean and green continues to grow.

As we promote so often at IntelliFinishing, independent studies have shown that our unique chainless power and free conveyor can save over 40% on utility bills when compared to the antiquated monument systems. This held true for this project as well, but there were other innovations that helped as well.

Simply replacing the 6 open-faced paint booths with a single automated booth went a long way in reducing energy use on the booths themselves, as well as the air handling units used to condition air going into and air being exhausted from the paint line. Our conveyor line is also decoupled, allowing each drive section to operate independently, only running when a carrier is present. The same could be said for the process washer as well. So while a monument system may have two or three large motors pulling chain continuously, the IntelliFinishing system breaks our conveyor down into much smaller sections that are controlled by much smaller variable speed drives. In this way, more motors does not equate to greater electricity usage, but actually reduced demands and added great flexibility.

The process equipment used in IntelliFinishing systems is also a step above the industry norm. Our oven and washer panels are insulated to help keep chemical tanks and curing chambers at temperature. On average this makes our process equipment 75-80% more energy efficient. Automated product doors also help to prevent heat loss. As a side note, the insulated ovens we incorporate in our systems also prevent accidental burns of employees. Even running at temperature, you can place your hand on the sidewall.

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Read Part II

Read Part IV

Part II: Safety–Not an Afterthought

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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.

Another challenge at the top of our customer’s needs was creating a safe work environment. With their existing manual system, the physical demand on the operators of lifting and loading parts through the various processes was excessive. The existing system was also very loud and difficult to keep clean with the several open-faced paint booths used to coat their parts.

Again, IntelliFinishing was able to incorporate several pieces of equipment into the system that all worked together seamlessly for a safe, quiet, and productive paint line. The first step was adding a lowerator to assist the operators in racking parts. The lowerator takes a carrier from the height of the process equipment down directly to the parts. This makes loading much easier, especially on heavier parts, and prevents stretching or straining when loading or unloading.

To limit chemical exposure to the operators, a multi-stage automated washer was added to improve the efficiency of chemical use and provide controlled containment of the chemicals as well. By reducing the overall usage of the chemicals our customer also reduced their chemical emissions to the environment, which was an added benefit.

Other safety factors that were built into the design included laser area scanners that stopped the conveyor when personnel or fork trucks were present in specified “danger zones” and insulated process equipment and special ducting to keep noise levels significantly below the 75dB required. The noise reduction in the paint line led to over 25 employees being removed from our customer’s hearing conservation program. Like my father always said, “A great paint line should be seen, and not heard.”

Though I suppose he may have been talking about us children.

Contact us today to find out how we can make your paint operations safer, quieter, and more efficient.

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Read Part IV

Part I: The Walls Are Closing In

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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!

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