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The Client
Generac Power Systems, Inc. manufactures a full line of commercial and home generators, including the Guardian® Automatic Home Standby generator. Operating from three plants in Wisconsin and one in Iowa, Generac offers customers security and safety for home and business.

The Challenge
In 2003, the largest blackout in North American history left millions of people without power. This event, coupled with numerous natural disasters, led individuals and companies to realize their vulnerability to power failures and to seek solutions to protect themselves. Since then, Generac’s business has been steadily increasing, necessitating the upgrade of their powder coating system to increase capacity and meet market demand.

The Solution
Being a customer of Gema USA for many years, Generac decided to stick with the proven record of reliability and service and chose to upgrade to Gema’s new OptiSystem.™ At their Whitewater, Wisconsin plant, Generac added OptiGun™automatic powder guns, OptiTronic™control units, and OptiFlow™ high-performance powder pumps to their existing line. For touch-up work, an OptiFlex™ manual powder coating unit was also included.

The Savings
Upgrading to the OptiSystem from Gema USA has resulted in financial savings for Generac. The high performance of the OptiGuns has equated to a 25% improvement in transfer efficiency, while recoats have been reduced by 20%. “Having pre-programmed settings is really a plus for training new painters,” remarked Wayne Brown, Production Supervisor, “The control and automation of the new system, coupled with the efficiency of the OptiGuns has meant higher productivity, better finish quality, and lower operating costs.”

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.