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 Gema USA. 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.

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