Custom Coaters

Modean Industries enjoys a long-term relationship with the job shop market not only in the United States but throughout Asia and the Middle East. Powder as well as liquid job shops are essential contributors to the finishing industry and are often the pioneers in the coating process of a specific market. In many circumstances, a client starts by utilizing the expertise offered through a job shop before deciding on installing their own coating system.

Modean Industries, in cooperation with its supplier, ITW Gema as well as its other affiliates, has played a major role in the design and installation of powder coating systems in the lighting fixtures market for both commercial and residential applications.

Case Studies

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Exceeding Expectations on Quality, Flexibility, Throughput and Cost Savings

The Client
“Give our deodorant product a new, flamboyant look that will pop off the shelf at the point of purchase.” That was the command handed down to the Packaging Group of a major manufacturer of consumer personal products.

The Challenge
As soon as it left Marketing, the concept was on a fast timeline to Production. A process was needed that would transform a polypropylene injection-molded part into a brilliantly colored, attractive finished cap with good surface durability.

In addition to being eye-catching, the new container concept needed to be environmentally-responsible, low-cost to manufacture and capable of being scaled to high volumes in the tens of millions per year.

The Solution
Modean Industries teamed up with a specialty coatings supplier, a vacuum metallizing equipment producer and a designer of precision spray coating machinery to come up with a solution that offered these benefits and more.

First objective achieved – the coating. A tinted clear, 100%-solids, UV-curable paint was conceived and developed in multiple colors. This custom coating offered:

  • EPA compliance – No VOC’s or HAP’s
  • Fast cure process time at low temperatures
  • Excellent flow and surface finish with no shrinkage
  • Capability for being applied over delicate vacuum metallized surfaces
  • Outstanding physical performance characteristics, look and feel

The next goal was to perfect a spray finishing process that would be highly-efficient and capable of meeting world-class quality standards. The result of the project team’s efforts included:

  • A super-efficient electrostatic rotary atomization process
  • A workholder concept that provided a grounded attraction for the electrostatic field
  • A precision spindle conveyor to transport and rotate the vacuum metallized conductive workholders
  • A spray booth with integral paint material reclaim capabilities
  • A UV cure chamber that is high speed, compact, safe and cool
  • A clean room built to suit the metallizing, transfer and painting processes

Time was of the essence in meeting the product’s introduction dates. Meetings and tests were conducted to verify the team’s designs and assumptions. The installation and commissioning of the system continued 24/7 until the line could be turned over to the client for him to turn the key and start production – right on schedule.

Benefit to Client
What was conceived as an interim solution or pilot line became the full production system. The line met or exceeded the client’s needs for:

  • Quality – State-of-the-art process control allows the paint system yield to top 99%.
  • Flexibility – Fast color change allows a quick transition from painting pink to blue.
  • Throughput – The system produces over 7000 parts per hour.
  • Work-in-process – The entire process of molding, metallizing and painting is completed in several minutes, minimizing inventory and client costs for storage and transport of goods.
  • Cost savings – The high-efficiency spray and paint reclaim techniques minimize waste and maximize parts/gallon.
  • Space savings – A clean room of 20 by 30 contains the entire paint line operation.

Conclusion
The result of the Modean project team approach was a system that realized the client’s vision – a fast, controllable process, durable and flexible equipment, an EPA-compliant installation and, most importantly, a means to achieve the designer’s dream of a product that feels as good in the hands of the consumer as it looks.

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Allan Industrial Achieves a Savings of $15,000 a Month in Powder Alone

Please note: The following Case Study has been prepared by ITW Gema, a supplier of Modean Industries, and is being reproduced with ITW Gema’s permission. Hani Azzam of Modean Industries supervised the design and engineering of several of the original Gema systems in the United States.

The Client
Allan Industrial Coatings, located in Allison, Iowa, is the Midwest’s premier coating job shop. Allan was founded in 1979 by Dave and Monte Allan, who still participate in management of the company along with current owner, Steve Hayes. Currently operating out of two facilities in Allison, one facility houses sandblasting and liquid coating operations, while the other 60,000 sq. ft. facility is dedicated to their powder coating operations. These facilities can accommodate small parts up to some of the largest parts in the industry, including products such as agricultural and recreational equipment, store fixtures, and computer components.

The Challenge
Although Allan received a quality finish with their ITW Gema Easy Series™ manual powder guns, they realized the need to upgrade to an automated system that would enable them to grow their business and meet customer demands. Allan wanted equipment that would reduce powder usage, increase production throughput, increase film thickness consistency, while still maintaining a high quality finish and reducing costs.

The Solution
Equipment capabilities, turnaround time, and the best value solution were major factors in choosing ITW Gema. Allan decided on the Magic Cylinder® booth, OptiGun® automatic powder guns, and OptiTronic Plus™ control units. Two OptiFlex™ Manual Wall Units were also installed for touch-up work.

The Savings
As a result of the upgrade, Allan increased their productivity, reduced powder usage, improved film thickness consistency, lowered rejects, as well as overall operating costs. “With the savings we are recognizing, the upgrade will pay for itself in one year,” stated Brian Fecht, Plant Manager.

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“We Couldn’t Stay Competitive Without an Upgrade…”

Please note: The following Case Study has been prepared by ITW Gema, a supplier of Modean Industries, and is being reproduced with ITW Gema’s permission. Hani Azzam of Modean Industries supervised the design and engineering of several of the original Gema systems in the United States.

The Client
Profile Powder Coating, founded in 1989 and located in Rogers, Minnesota, provides cost-effective finishes for metal and MDF wood composites. With an emphasis on quality and service, Profile strives to achieve fast turn-around times to their customers without cutting corners on the integrity and quality of the finish.

The Challenge
Quick color change and updated technology were important to Profile in their consideration of a new powder coating system. They were also looking for faster line speed, more automation and lower rejects.

The Solution
ITW Gema’s Magic Cylinder® powder coating booth was the solution chosen by Profile. They were impressed with its unique, round-wall design and quick color change options. An OptiSystem™, including OptiGun AX™ automatic powder guns, OptiTronic Plus™ control units, and OptiFlow™ pumps, was also installed. Completing their quick color change system is a Chameleon™ Color Management System.

The Savings
According to Steve DeJong, “ITW Gema’s knowledgeable staff has provided us with the hands-on training we needed to run our new system at peak performance and achieve optimum results.” These results include producing higher quality finishes, while increasing the line speed by 30%. Ten minutes have been shaved off their color-change time and they have achieved powder savings of 40%.

“Our new Magic Cylinder powder system gives us the quick color change capability we needed and the financial savings we were looking for.”
— Steve DeJong, Profile Powder Coating

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ACM’s Upgrade Provides Reliable Powder Coating

Please note: The following Case Study has been prepared by ITW Gema, a supplier of Modean Industries, and is being reproduced with ITW Gema’s permission. Hani Azzam of Modean Industries supervised the design and engineering of several of the original Gema systems in the United States.

The Client
Augusta Coating & Manufacturing (ACM) is a full service contract coater of steel, stainless steel, and aluminum parts. ACM specializes in high corrosion and appearance coatings for the transportation, automotive, agricultural, electrical, and recreational and maintenance vehicle markets.

The Challenge
Having high reject rates when coating with metallic powders on extremely challenging parts, ACM realized the need to upgrade their powder coating equipment. The goal was to obtain a reliable and repeatable process which would reduce overall costs and increase flexibility in order to adapt to changing customer requirements.

The Solution
After lab demonstrations from several suppliers, ACM found the only powder coating equipment that met their needs was the OptiFlex™ Automatic Powder Coating system from ITW Gema. ACM’s upgrade consisted of OptiGun® automatic powder guns, OptiStar™ control units, OptiFlow™ powder pumps, OptiFlex manual wall units, and an OptiFlex manual box unit.

The Savings
Through the consistent and reliable application of metallic coatings on their challenging part geometries, ACM has recognized numerous benefits from their ITW Gema upgrade. ACM has reduced their rework costs and associated employee overtime, decreased throughput time, reduced spare parts usage by 20%, and reduced powder usage by 20%. ACM estimates a payback time under one year for the purchase of the new ITW Gema powder coating application equipment.

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