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Take Simple Steps to Avoid Powder Delivery Errors
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High Performance Lawn Mower Manufacturer Cuts Powder Usage with ITW Gema's OptiFlex® Manual Units!
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Product Spotlight: ITW Gema's 2009 Powder Coating Application and Maintenance Classes
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Free Optimization Assessment.

Find out how your
company can
Save Powder and Improve Transfer Efficiency!
Dixie Chopper did!
Click Here.
______________________________



Indiana maker of world-class lawn care equipment uses 50% less powder, while experiencing superior transfer efficiency and uniform film thickness!

Part 1 in a 3 Part Series:
Powder Delivery
Troubleshooting Tips...
Powder Feed Surging

In powder coating, control of the powder delivery is critical to the performance of the application. Charging efficiency and applied film thickness uniformity are dependent upon consistent powder delivery. There are many variables that affect uniform powder application. In this edition of the GemaGram, we'll examine Powder Feed Surging and how to correct it.

Surging is typically the result of an inconsistent compressed air supply, or blockage in the powder pump or feed line, causing the powder to puff or surge out of the powder feed line and cause a reject. Following are problems that can cause or contribute to surging and the solutions:

Inconsistent Compressed Air Supply
• For a quality compressed air supply, maintain the correct
• volume of air available for the powder paint system.
• Clean, dry air is important.
• The compressed air supply feeding the powder system
• needs to be conditioned.
••- This is accomplished with a properly sized air dryer.
••• Either a refrigerant or regenerative air dryer is
••• acceptable. When the air volume required is 500 scfm
••• or greater, a regenerative unit may be preferred.
••- Other items required with the air dryer are a particle
••• filter and a coalescing filter. It is best that the filters
••• in the system be set up with automatic drains or flags
••• that indicate when service or replacement is required.

Powder Pump or Feed Line Blockage
• Maintain air quality.
••- Requirements are: Maximum oil content or 0.1 ppm,
••• dew point of 35 degrees F or lower and particulate
••• matter no larger than 10 microns.
• Keep the powder free of moisture, oil and other dirt.
••- Powder will fluidize more evenly and the pump can lift
••• the powder through the suction tube more easily,
••• transporting the powder to the gun more efficiently.

Impact Fusion Inside Hoses and On Gun Components
• Performing periodic maintenance can avoid this problem
••- Follow the manufacturer's guidelines for regular checks
••• and cleaning of the components in the powder path.
••• This includes the gun tips, electrodes and pump inserts.
••- To prevent additional build-up, never leave the powder
••• hoses full of powder at the end of shifts or overnight.
••• Before shutting down the system, use compressed air
••• to blow the lines and guns free of residual powder. As
••• a regular rule, this should also be done at the end of
••• each shift and before going on breaks.

Uneven Fluidization
• Minor adjustment in fluidization pressure.
••- Uneven fluidization can cause too little or too much air
••• in the mixture at the suction tube. Fluidization should
••• be an even and uniform soft boiling in the feed hopper.

Obviously, good, consistent and high quality compressed air means everything to obtaining a superior powder coating finish. Like the air that we breathe, the higher the quality, the better... and one less variable to worry about!

In the next edition of the GemaGram, we'll tackle Hopper Fluidization.

Now Available!
The Third Edition of The Powder Coating Institute's POWDER COATING: The Complete Finisher's Handbook. Click Here to Get Your Copy.

"The OptiSelect® gun is much lighter and easier to use than our old guns."

Angelita Church,
Dixie Chopper

“We're saving money and getting better coverage with our new OptiFlex® units!”

THE COMPANY
Art Evans manufactured the first Dixie Chopper® in 1980, and continues to produce some of the best zero-turning radius mowers on the market. Family-owned and operated, Dixie Chopper operates a large manufacturing plant in the midst of picturesque farm country near Greencastle, Indiana. The longevity of Dixie Chopper's business is a testament to their commitment to producing mowers that perform for many years after the mower has been paid for. In 2004, Dixie Chopper teamed up with Orange County Choppers (from the popular cable TV show American Chopper) and commemorated their 25th anniversary by merging mower and motorcycle into a one-of-a-kind work of art chopper (see it at Dixiechopper.com). In keeping with their philosophy of quality and performance, when their powder coating equipment started to age, Dixie Chopper opted to upgrade to new OptiFlex® manual powder coating units from ITW Gema. "Our older powder coating guns were breaking down more and more often, and parts were becoming harder and harder to get," commented Tiffany Albright, Fabrication Operations Manager. "Downtime for repairs was becoming a real issue."

THE RESULTS
ITW Gema's distributor, American Industrial Corporation, installed two OptiFlex wall-mounted units in Dixie Chopper's powder booth, and the results were immediately noticeable. They are now able to maintain control over the coating process due to the OptiFlex's ability to store custom programs. Operators no longer "car wash," spraying more powder than necessary and wasting money. Transfer efficiency dramatically increased, and there has been an obvious reduction in the amount of powder being sprayed. "We were really surprised how much we've saved on powder since we started using the Optiflex units," Tiffany remarked. "Our powder consumption has been reduced by 50%, and we're achieving much better coverage."

Power Up Your Productivity
...like Dixie Chopper

Coat it right the first time – every time, and...
• Minimize Downtime
• Spray Less Powder
• Reduce Labor Costs
• Experience Fewer Rejects

Click here for more information!

ITW Gema not only designs and manufactures the world's leading automatic and manual powder coating equipment, but we provide world-class training, too!

ITW Gema offers two-day training classes at our facility in Indianapolis, Indiana, for those individuals interested in learning the ins and outs of powder coating with ITW Gema equipment.

Who should attend? Operators and persons responsible for the use, maintenance and upkeep of ITW Gema electrostatic powder coating equipment will benefit from this course. Companies that want their employees to learn proper and efficient powder coating techniques, as well as troubleshooting and maintenance skills, should plan to attend, too.

Attendees will learn how the equipment is designed to work, then how to use and maintain it. The classes consist of a lecture conducted by ITW Gema's experts, along with a hands-on applications session conducted in our lab and led by ITW Gema's Sales Lab Manager and Lab Technician. You can even coat one of your own parts. See the registration form for requirements.

We offer courses at various times of the year that cover automatic and manual systems or just manual systems alone, so you can easily fit them into your schedule.

However, these classes are popular and tend to fill up fast, so the sooner you sign up, the better!

To register for 2009 Application and Maintenance Training classes, see the schedule listed at the left or visit www.itwgema.us

Does your company
need to optimize?
––––––––––––––––––––––––––––––
• Are you wasting powder?
• Are you experiencing too
• many rejects?
• Is your equipment older
• than 5 years?
• Are your labor processes
• inefficient?
• Is your film thickness
• inconsistent?
• Is your business growing?
• Has your equipment been
• rendered obsolete by the
• original manufacturer?

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ITW Gema An Illinois Tool Works Company
P.O. Box 88220, Indianapolis, IN 46208-0220
Phone: 1-800-628-0601 • Fax 317-298-5010

www.itwgema.us
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