The Client
Hydro Aluminum is a leading aluminum extruder and the largest drawn tubing producer in North America. With 11 aluminum extrusion facilities, customers can count on getting the right metal at the right time. Their St. Augustine, Florida facility specializes in the contract manufacturing and finishing of a wide variety of extrusions. Examples include wind chime tubing, aluminum boat decking, awning components, soccer goal components, and compressed air
piping systems, along with other specialty products.

The Challenge
Having extensive experience with a liquid electrostatic finishing system, Hydro Aluminum wanted to bring the benefits of powder coating into their operation. Their initial powder coating system included manual guns from Gema USA. However, the company soon realized that a higher level of automation was required to achieve the consistency and quality their customers demanded.

The Solution
Hydro Aluminum chose Gema USA for their powder system upgrade, based on their positive experience with Gema’s manual guns and the excellent service from Gema USA’s distributor, Dietz Supply Company. Hydro Aluminum installed a 9000 cfm Gema USA cartridge booth, fitted with OptiGun® automatic powder guns, OptiStar™ control units, and OptiFlow™ high performance powder pumps. A 30’x 65′ environmental clean room was supplied by Dietz Supply.

The Savings
Upgrading to Gema USA’s OptiFlex™ automatic powder coating system resulted in numerous benefits for Hydro Aluminum. “Having a system that maintains consistency every time, has reduced the number of rejects and improved the quality of our finished products,” stated Scott Johnson, Regional Engineering Manager. Hydro Aluminum can now target new customers with higher coating requirements.

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.