The Client
Lippert Components, a Drew Industries subsidiary, manufactures specialty trailers at their Milford, Indiana plant that are fully customizable for hauling a wide variety of items.

The Challenge
In the past, Lippert had been a liquid coating operation. They turned to powder coating to achieve a better finish that was both environmentally friendly and cost-effective and decided to place an automatic powder coating line at the Milford plant. Quick color change and low powder consumption were significant factors for the installation. Since Lippert is a spray-to-waste operation, transfer efficiency was a very important consideration.

The Solution
Lippert’s Milford facility chose an automatic line from Gema USA. A 20,000 cfm Diamond™ booth contains sixteen OptiGun™ automatic powder guns, OptiTronic Plus™ control units, and OptiFlow™ pumps. The system also includes an AutoTracker™ Programmable Logic Controller (PLC) and Chameleon™ Color Management System.

The Savings
The combination of OptiSystem™ components, along with the AutoTracker and Chameleon, has enabled Lippert to realize greater application efficiency than they had experienced in the past. Since they do not reclaim powder, achieving the best coverage with the least waste is very important. Decreasing consumables and optimizing powder consumption have resulted in a highly cost-efficient operation, factors that have contributed to a payback in 24 months.

“High transfer efficiency and savings on consumables has really made our new system pay off.”
— Cliff Boyer III, Lippert Components

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.