‘Green’ Products
Modean Industries, in cooperation with its Affiliates, Aztech Engineers, SolarOne Solutions and ITW Gema, has played a major role in the design and installation of pollution-FREE, powder and 100% solid UV coating systems in the renewable energy market for both commercial and residential applications.
Case Studies
- Producing a Superior Product While Maximizing Cost Savings
- Creative Solutions for Complex Coating Challenges
- Lightolier/CFI Increases Productivity by more than 72%
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Producing a Superior Product While Maximizing Cost Savings
The Client
A multinational automotive aftermarket manufacturer with a unique patented product.
The Challenge
The client was experiencing problems with his coating process required to meet the stringent standards imposed by the automotive industry. Find a system that incorporated two unique coating processes.
The Solution
Modean Industries visited the client at their facility and studied the detailed requirements and space available. Extensive tests were made in the surface preparation of the aluminum extrusion that included the evaluation of highly polished surfaces to a conversion coated surface. The most economically feasible system, designed to meet the imposed standards set by the automotive industry, proved to be the following approach:
- First and foremost the proper cleaning of the base aluminum surface. Here Modean Industries supplied a 4-stage washer and dry-off oven to accomplish the cleaning process.
- Next applying a highly-loaded metallic powder base coat. This was done in a cartridge filter booth that included ITW Gema automatic guns on oscillators.
- Curing the base coat. This was accomplished in a convection-type oven capable of reaching 500 deg. F.
- Re-coating with a very clear powder coating to provide the exterior (UV) protection for the metallic powder; again, this was done in a cartridge filter booth that included ITW Gema automatic guns on oscillators
- The final cure was also done in a separate convection oven capable of reaching 500 deg. F.
Several samples were prepared and submitted to the automotive industry in Detroit for approval. Again, after extensive tests, the process and the coatings were approved and the client issued a purchase order to Modean Industries. This system was a total turnkey that included installation, training and start up.
Benefit to Client
The client now had a new ystem that met his needs for:
- Meeting all local and federal environmental standards,
- Providing a superior product while maximizing cost savings, and
- Eliminating production bottleneck
Conclusion
This was a unique solution to a very complex problem. The system has been operating successfully for several years with outstanding results and has been accepted throughout the automotive, automotive aftermarket and consumer retail markets.
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Creative Solutions for Complex Coating Challenges
The Client
A major US manufacturer of commercial and residential lighting fixtures.
The Challenge
This was an especially complex project. Working with the client, the engineering department came up with several design innovations to tackle the following specific challenges:
- Cost Management – Justify the cost to transition from an existing liquid paint system to a powder coating system not just in one plant but in two separate plants, in two different states, while insuring full regulatory compliance for both states’ strict solid waste and pollution control requirements.
- Space Limitations – Space conservation was a major consideration and not a simple one at that. The new powder coating system consisting of powder booths and recovery system had to be squeezed into the space occupied by the existing liquid system.
- Downtime Constraints – The finishing line could not be down for more than two weeks. This was the time allotted for tearing out the old liquid system and installing the new powder application system.
The Solution
Initially the client considered installing an entirely new finishing system, including a new washer and oven as well as the powder application system that would be erected in a new building add-on. Instead, the existing liquid paint line was converted utilizing their existing washer and ovens. For the powder coating system the client selected the twin-air-belt system which would not only accommodate their multi-color system and conserve space but the new quick-change belt design would make color change relatively easy.
Next was confronting the space limitations. The new powder system would be placed in the same space occupied by the old liquid system. Since there was no space for the complete system on the same floor, the engineers decided to look up and designed a plan so that the exhausters for the system’s two automatic spray booths would be located on the roof of the building. This innovative idea accomplished two things: noise levels inside the plant were greatly reduced and it eliminated the need for subfloor cabling which would have been required if they had to tear up the floor slab to route electrical cables and powder supply hoses.
Although this approach saved money, it was not without its problems. The finishing line could not be down for more than two weeks and that was the time allocated for tearing out the old liquid system and installing the new powder application section. Careful planning and preassembling as much of the equipment as possible, the client, assisted by the supplier’s service personnel, met his deadline. The system was fully operational at the end of two weeks.
Benefit to Client
With two new powder coating systems in both plants, the client estimates that the overall cost savings will exceed his original projections. The advantages of the powder system installed were:
- First and foremost, a product that looks great with a more durable finish
- Lower material and labor costs
- Reduced air make-up and consumption of compressed air
- Elimination of sludge and hazardous waste disposal and pump repair costs
- And finally full compliance with both states’ strict solid waste and environmental pollution regulations.
Conclusion
The results of the new powder coating system speak for themselves. We were able not just to achieve the client’s requirements, but exceed them: coating products with a superior finish applied at a lower cost; improving utilization of the coating material by 50+%, complete compliance with environmental regulations; and eliminating VOC emissions. The added bonus was a clean paint line that made housekeeping a cinch!
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Lightolier/CFI Increases Productivity by more than 72%
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
Lightolier/CFI, a member of the Genlyte Thomas Group LLC family of companies, is a leading manufacturer of lighting fixtures and controls for commercial, industrial and residential markets.
The Challenge
When Lightolier’s equipment began to age, they knew it was time for an upgrade. Christian Rheault, Manufacturing Manager, relied on Lightolier’s long-standing relationship with ITW Gema to build a new system that was right for their operation.
The Solution
Lightolier upgraded to a complete OptiSystem from ITW Gema. The upgrade also included an 8,000 cfm Vortech™ powder booth and an AutoTracker™ Programmable Logic Control (PLC) that was integrated with their computer network.
The Savings
Lightolier has been able to increase both line speed and product density, easily meeting their expanded production requirements. Due to better transfer efficiency, they also achieved powder savings of 28%. They expected a return on their investment in eighteen months, but achieved it in less than 6!
“Prior to our upgrade to the OptiSystem™ we were producing 2,500 parts per day running ten shifts per week. Now we can produce 4,300 parts per day with only eight shifts — and we’re still improving!”
— Christian Rheault, Lightolier/CFI