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Take your powder coating in the right direction, by using the right gun nozzle.
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ITW Gema® Powder Coating Equipment is the vehicle custom coater uses to increase productivity and lower costs!
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Product Spotlight:
ITW Gema's NEW MultiSpray
Nozzle Adapters
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Free Optimization Assessment.

Find out how your
company can
Get Better
Powder Coating Equipment Reliability and Flexibility
Augusta Coating & Manufacturing did!
Click Here.
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Georgia custom coater gets the flexibility they need to respond to their customer's ever changing finishing requirements!

Keep Your Spray Pattern "Birdens" Caged –
Use the Spray Nozzle that's Right for Your Application!

There are two basic types of nozzles to select for your ITW Gema powder spray gun–flat or round spray nozzles. Most commonly used on automatic guns is the flat spray nozzle, while manual guns use both styles. Many manual users find that the round spray or "deflector/conical" nozzles provide improved coverage. The nozzles for ITW Gema's manual OptiSelect™ gun and automatic OptiGun® are interchangeable.

Flat spray nozzles provide a uniform pattern with forward velocity, more so than round spray nozzles. These nozzles are very effective with target distances from 6-12", and can help the powder reach recessed areas of profiled parts.

Round spray nozzles produce a softer round spray pattern and are most effective with close target distances, such as manual touch ups of Faraday Cage areas. Using a flat spray nozzle at a very close target distance may result in blowing the powder off the part. When using a round spray nozzle, the forward velocity is broken by the deflector as it exits the gun, softening the powder cloud velocity.

Whether choosing round or flat spray, there are different sizes of nozzles available. Often manual gun users opt for the small deflector (16mm) for their round spray nozzles if they are touching up parts that are coated by automatic guns. The 16mm nozzle provides a tight, round pattern of about 3", allowing the operator to direct the powder cloud into corners of parts or recessed channels that are often narrow. If the user must coat the entire part with only manual guns, a larger deflector may be selected that produces a larger spray pattern. Deflectors range from 16mm to 70mm for ITW Gema guns.

Flat spray nozzles are ideal for automatic guns because they produce a wide effective spray pattern that can be considered when calculating how many guns are needed for an application. For example, a standard flat spray nozzle will produce an effective pattern of 10" at an 11" target distance. Therefore, 6 automatic guns with vertical spray patterns would effectively cover 60" of product height. Flat spray nozzles are also available in different sizes. Nozzles with larger slots will generally provide a wider spray pattern as well as lower velocity. This is useful for applications with high powder outputs. Nozzles with narrow slots will concentrate the powder into a tighter spray pattern and increase the spray velocity. This is ideal for target guns or guns used to penetrate into deep recesses.

ITW Gema has recently introduced a MultiSpray Nozzle Adapter. The MultiSpray Adapter fits over existing flat spray nozzles and can be adjusted to create three new pattern widths. This adapter can be used on automatic or manual guns, but is most suited for manual guns using flat spray nozzles because the operator can adjust the nozzle as needed while coating parts. Position 1 is a wide pattern, while position 2 and 3 are narrower. Typically, operators would use position 3 to apply powder in deeper cavities. The adapter would then be reset to position 1 to fill in areas and build film specifications. For more information, see the GemaGram "Product Spotlight" below.

ITW Gema also offers nozzles for porcelain enamel and tribo guns, along with specialty nozzles, such as metallic nozzles.

Contact your local distributor or ITW Gema Technical Service at (800) 628-0648 for more information on ITW Gema products. Or visit www.itwgema.us

"Upgrading to ITW Gema has helped us meet changing customer requirements by providing a reliable coating process, while reducing costs to meet the financial challenges of today's business climate."

Bud Rehl,
Augusta Coating & Manufacturing

“Our ITW Gema upgrade provides reliable powder coating unavailable from other suppliers!”

THE COMPANY
Augusta Coating & Manufacturing (ACM) is a full service contract coater of steel, stainless steel, and aluminum parts. ACM specializes in high corrosion and appearance coatings for the transportation, automotive, agricultural, electrical, and recreational and maintenance vehicle markets.

THE CHALLENGE
Having high reject rates when coating with metallic powders on extremely challenging parts, ACM realized the need to upgrade their powder coating equipment. The goal was to obtain a reliable and repeatable process which would reduce overall costs and increase flexibility in order to adapt to changing customer requirements.

THE SOLUTION
After lab demonstrations from several suppliers, ACM found the only powder coating equipment that met their needs was the OptiFlex™ Automatic Powder Coating system from ITW Gema. ACM's upgrade consisted of OptiGun® automatic powder guns, OptiStar™ control units, OptiFlow™ powder pumps, OptiFlex manual wall units, and an OptiFlex manual box unit.

THE SAVINGS
Through the consistent and reliable application of metallic coatings on their challenging part geometries, ACM has recognized numerous benefits from their ITW Gema upgrade. ACM has reduced their rework costs and associated employee overtime, decreased throughput time, reduced spare parts usage by 20%, and reduced powder usage by 20%. ACM estimates a payback time under one year for the purchase of the new ITW Gema powder coating application equipment.

Click here to view the entire Augusta Coating
& Manufacturing case study!

Product Spotlight:
NEW MultiSpray adapters are available for ITW Gema guns!

New MultiSpray adapters are available for the standard flat spray nozzle (NF08 30mm) and the wide spray nozzle (NF10 40mm). This adapter adjusts the powder cloud in 3 positions, giving the manual gun user more flexibility over pattern control when using a flat spray deflector (see example below). The mechanical connection is designed to clip on the Teflon nozzle. These new adapters will fit on existing nozzles without the need for additional parts.

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

www.itwgema.us
gemagram@itwgema.com

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