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 Gema USA, 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

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.