Fabricated Metal Products

Modean Industries’ experience with fabricated metal products covers a broad range of products, including but not limited to: fire arms, security and metal fences, industrial metal partitions, door handles and hardware, athletic equipment and satellite dishes. The combination of Modean Industries’ system design experience coupled with the exceptional quality of application equipment supplied by the ITW Group of companies has afforded our clients many years of trouble-free, dependable finishing systems.

Case Studies

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Market Leader in Fire Arms Achieves Full Compliance with Environmental Regulations

The Client
A top market leader in fire arms and law enforcement products with international revenues in excess of $200 MM per year and a prestigious position in the industry.

The Challenge
State and federal regulations had come to restrict the use of the company’s existing coating process and they needed to engineer a change that would meet not only government environmental regulations but also requirements specified by the fire arms industry.

After a complete evaluation of the problem, Modean Industries, along with its client, contacted a chemical research and development company to create the new coating. With the help of ITW Ransburg, numerous tests were preformed at their test lab simulating actual production conditions and in the process allowing Modean Industries to design the racking system to meet the unique just-in-time production requirements.

Once the system was installed and operating, the client began experiencing problems with the coating supplied by the R&D company. Under normal circumstances, a system house’s responsibility ends when the start-up is complete. Although it had nothing to do with Modean Industries, they were not willing to leave its client with an unresolved production issue. Upon further investigation by Modean Industries it became apparent that even though the R&D company was capable of making excellent research samples, it did not have the capacity to perform material production runs. Knowing this, Modean Industries sought out among its contacts a chemical production company that could meet the controlled production of the new coating.

The Solution
The new system was designed employing high speed rotational atomizers (Aerobell) that provided not only the desired physical appearance but excelled in the actual test requirements imposed by the industry. Adding to the challenge, Modean Industries had to develop the system and factor into its design the customer’s plant space limitations. Here again Modean Industries utilized its innovative approach and set the complete system including load, material application, flash-off time, curing, unloading and cooling all in an area that measured approximately 8 feet wide by 11 feet long by 22 feet high.

Benefit to Client
The client was now in full compliance with federal and state environmental regulations. By automating the process, the new system increased production and the new coating not only met but exceeded the physical specifications required by the fire arms industry. Further, by the using the Aerobell electrostatic system, the process was more efficient, less expensive to operate and provided a superior finish.

Conclusion
The client was extremely pleased with the results, especially with Modean Industries’ commitment to the project. In fact they purchased a second system from Modean Industries and retrofitted an existing painting facility with the new Aerobell system.

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American Products Overcomes Paint Line Bottleneck

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
American Products is a major regional supplier of precision custom metal stamping and fabrication. They also provide powder coating, product development, assembly, and packing services from their two Missouri locations.

The Challenge
After a series of downsizing and new ownership issues, America Products was left with a mixture of equipment that was aging and inefficient. The powder booth was so cumbersome to clean, that it took three hours to do a color change. American Products needed an upgrade!

The Solution
After looking at various competitors’ solutions, American Products chose a new 12,000 cfm VortechPlus™ booth from ITW Gema. They completed their upgrade with OptiGun-2AX™ automatic powder guns, OptiFlow™ pumps, OptiTronic Plus™ control units, a Chameleon™ Color Management System, an AutoTracker™ Programmable Logic Control (PLC), gun movers, and light curtain part recognition.

The Savings
“We went from a three-hour color change to twenty minutes with one operator,” stated Steve Smith. “Our powder recovery rate is at least 95%, we’re saving $20,000 a month in labor and scrap for reworks, and we’ve reduced our powder usage by about 30%. I wish we would have done this a long time ago!” American Products calculated a payback of 14 months; however, according to Steve Smith, the figure is really much lower due to the realization of savings in areas not included in the original payback formula.

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Hadrian’s Upgrade Dramatically Improves Efficiency

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.

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The Client
Hadrian Manufacturing Inc. is a manufacturer of high quality bathroom partitions and lockers in a variety of designer colors and special effect finishes.

The Challenge
Because Hadrian strives to offer high-quality, durable products that can withstand the test of time, they are constantly seeking ways to achieve those goals, while at the same time maintaining optimum efficiency. That’s why, when Hadrian wanted to lower their powder consumption and speed up their color change time, they turned to ITW Gema to upgrade their equipment.

The Solution
Hadrian upgraded to ITW Gema’s OptiSystem™, installing OptiGuns™ and OptiTronic™ Control Units. To maximize their efficiency, a five-zone vertical light curtain part recognition system was integrated with Hadrian’s existing PLC to give them accurate automatic gun triggering and repeatable results.

The Savings
The OptiSystem’s precision control and accuracy has enabled Hadrian to save money. Faster color change time and less time lost due to maintenance has greatly improved their efficiency. The uniform air volume control and high first-pass transfer efficiency of the OptiSystem has created powder savings of 15%, while improving the quality and consistency of their finished products. With results like these, Hadrian expects a payback on their investment in only 12 months!

“We understand we have the best available equipment in the industry; therefore, we know we produce the best quality finish at the utmost efficiency.”
— Spencer McIvor, Hadrian Manufacturing Inc.

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Handles, Inc. Now Uses 30% Less Powder to Get the Same Coverage

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
Handles, Inc. is a division of the Thomas Monahan Company. Since 1922, the Thomas Monahan Company has been a manufacturer of high quality wood and steel handles for brooms, mops, shovels, and other implements.

The Challenge
When Handles, Inc. began to receive new contracts for large orders, they knew they would have to install a new system to keep up with the demand for their products. Only the latest in powder coating technology would do for Handles, Inc., so they chose a system from ITW Gema.

The Solution
The OptiSystem™ from ITW Gema was the answer for Handles, Inc., featuring OptiGun™ automatic powder guns and OptiTronic™ Control Units. The new system also included two powder booths and two interchangeable recovery systems: one with mini-cyclone separators and one with a cartridge-style filtration system.

The Savings
Handles, Inc. now has the capability to coat 133% more parts than they did with the old system. Taking into consideration that they also had a 30% reduction in powder consumption, upgrading to the OptiSystem truly exceeded their expectations!

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Payne Fence Sees Ten-Fold Productivity Increase After 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
Payne Fence Products, a division of Payne Metal Works, Inc., provides the highest quality and widest standard selection of Security and Architectural Metal Fence products in the industry. Payne Fence delivers a superior, cost-effective solution for any project requiring security or ornamental fencing and gates, with the company’s patent-pending fence and barrier systems, and custom designs.

The Challenge
Some of the nation’s largest retailers have turned to Payne Fence Products’ fence systems for their new and retrofit construction projects. The increased specification of Payne systems called for a larger, state-of-the-art manufacturing facility. An upgraded powder coating system was an essential element of the company’s dedication to meet each project’s targets, on time and on budget.

The Solution
Payne thoroughly investigated powder coating equipment suppliers for eight months before choosing ITW Gema. Equipment performance, five-year warranty, support and service, industry recommendation, and equipment reputation were major factors in their decision. Payne installed ITW Gema OptiGun® automatic powder guns, OptiTronic™ control units, and OptiFlow™ high performance powder pumps.

The Savings
Along with increasing their production capacity ten times, Payne Fence experienced an improved finish quality, consistency, reduced labor and downtime costs, quicker color change times, reduced powder usage and easier to use equipment. “Our painters really like the new equipment because it is much easier to use than what we had before. We thought headaches came with powder coating, but after installing ITW Gema equipment our headaches went away,” stated Donnie Keilers, Operations Manager.

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Pioneer Manufacturing Achieves Quick Color Change Capability

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
Pioneer Manufacturing, LLC manufactures metal products for the Rogers Group in Clare, Michigan. Among the companies under the Pioneer corporate umbrella is StageRight, a distributor of major event staging and seating risers, and Rogers Athletic, which produces a full line of football practice equipment and athletic training tools.

The Challenge
Previously, color changeovers took four to six hours with two operators. Color cross-contamination was a major issue, so the only realistic solution was limiting production to one color. Pioneer wanted to automate their manual system, increase productivity, and expand their line to provide a variety of color and finish options.

The Solution
Pioneer attended an industry trade show looking for quick color change technology. After investigating what the competition had to offer, Pioneer decided ITW Gema, and the Magic Cylinder™ booth, was the best solution. An OptiSystem™, including OptiGun™ automatic powder guns and OptiTronic Plus™ control units, was installed, along with two EasySystem™ touch-up units.

The Savings
As a result of their upgrade, Pioneer reduced finishing labor by more than 75%, while achieving extremely quick color changeovers. “With one operator we can do a complete color change in 3 minutes if we spray-to-waste and 5 to 10 minutes if we reclaim,” stated Kyle Camp, Plant Manager, “This system has really exceeded all of our expectations!”

“Before the upgrade we could offer our customers any color they wanted — as long as it was black. Now we have the fast color change capability to provide a wide variety of colors.”
— Kyle Camp, Pioneer Manufacturing, LLC

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Winegard Experiences Dramatic Increase in Productivity

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
Winegard® is a leading manufacturer of high-quality television reception products, and distributes over 1,000 various items across the United States and around the world.

The Challenge
Winegard’s paint line capacity for satellite reflectors was limited and uniformity was inconsistent. This problem wasted powder and made application of the logo to the reflector difficult. Dick Garnjobst, manufacturing engineer for Winegard, looked to ITW Gema for a solution.

The Solution
ITW Gema devised a system that would significantly increase the number of reflectors sprayed at a time. The upgrade included a new OptiSystem, with powder guns and control units.

The Savings
Winegard saw a drastic increase in production. Their coating thickness has been significantly reduced, translating to a 15% reduction in powder usage. Based on powder savings and cost, this translates into a total payback in less than 10 months.

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