The Client
Windsor Metal Finishing is a privately held company that specializes in architectural finishing. Located in Kissimmee, they are currently the only company licensed in Florida to provide the complete lines of high-performance fluoropolymer coatings compliant with the extensive requirements of the American Architectural Manufacturer’s Association’s (AAMA) Specification 2605-8.

The Challenge
Operating as a purely liquid coating facility, Windsor saw that there was an opportunity to expand their operation by offering high-end powder coatings capable of withstanding Florida’s harsh environment. The combination of high humidity, salt-laden air, strong UV rays, and abrasion from windblown sand, quickly cause fading and chipping and Windsor wanted to provide a solution to these problems. Florida’s “Green Building Movement,” encouraging businesses to provide more environmentally-friendly finishing solutions, created additional motivation to upgrade their operation with a powder coating line.

The Solution
Because part sizes can be large and vary significantly from job to job, a manual application technique was determined to be the best option. EasySystem™ touch-up units with OptiTronic™ controls were installed in a cartridge-style booth. The powered roll-on/roll-off booth gives Windsor the flexibility to perform both liquid and powder coating operations on the same conveyor line.

The Savings
The new system has been so successful that it helped Windsor to win the Governor’s 2004 Council for Sustainable Florida Small Business Award. As powder continues to grow and replace liquid coating applications at Windsor, disposal costs of volatile chemicals have been declining. Since the powder coated parts do not require a primer, the elimination of this step has led to time savings, as well as other cost reductions associated with the liquid process. The efficiency and cost-effectiveness of the upgrade, coupled with increased business volume, has enabled Windsor to realize double the profit level anticipated at the start of this project.

“When your powder costs more than $20 a pound, precise application becomes critical.”
— Malcolm Brant, Windsor Metal Finishing

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.