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Ya'll need to aim your guns better... and get a whole bunch more out of your reciprocator or gun mover.
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Midwest custom coater makes the shift from manual to automatic powder coating, with an upgrade from ITW Gema.
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Product Spotlight:
ITW Gema's OptiMove™ Reciprocator Control Unit
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Free Optimization Assessment.

Find out how your
company can
Reduce powder usage while improving finish quality.
Allan Industrial Coatings did!
Click Here.
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Midwest custom powder coating company upgrades to new ITW Gema automatic powder coating equipment, and saves so much in powder, that the investment will pay for itself in a year!

There’s powder coating in Dodge City, pardners, and we aim to get something straight! If you have an automated powder coating booth, chances are you also have some form of gun mover or reciprocator. These automated units move the powder coating guns up and down and in and out while spraying, according to preset control parameters. Although these movements are controlled by automation, it’s important to calibrate and set these functions specifically for the parts being coated. Correct settings will result in accurate and even coating of parts, with no large variations in film build. The best part is, that with a little time spent calculating the variables, you’ll get a whole heap of rewards when it comes to reducing unnecessary overspray, saving powder, and reducing the number of reworks and rejects. When the “smoke clears”, you’ve got a higher quality powder coating on your product!

There are two important aspects to consider when calculating gun position settings: Gun Stroke and Gun Spacing. Gun Stroke is simply the distance a gun is set to vertically move up and down when activated, between a point A and point B. Gun Spacing is the vertical distance between the guns when mounted to the reciprocator. If the Gun Stroke is set too long or Gun Spacing is incorrect, a pattern overlap of heavy bands of powder can result. If the Gun Stroke is too short, or if Gun Spacing is still incorrect, the guns may not meet properly, causing no pattern overlap, but creating light bands of powder. Either way, the part is not being coated properly, wasting time and money.

It’s fairly easy to calculate the Gun Stroke and Gun Spacing using the simple formulas below. The formulas also need to take into account the guns’ Spray Pattern (or Effective Pattern Height). Whether vertical, horizontal, round, or otherwise, make sure you have that information to plug in. Keep in mind that you figure the Gun Spacing measurement first and use that resulting number in the calculation of the Gun Stroke. Here are the simple calculations:



Click here to view a PDF of the calculation formulas

The Gun Spacing measurement can then be used to adjust the distance between the guns, by measuring with a ruler from the centers of the gun tips and adjusting the gun position until the guns are lined up properly. The Gun Stroke measurement is then input into the Reciprocator Control Unit. Obviously, if you significantly change the product dimensions, you would want to refigure your calculations to make the most of your powder savings and improve efficiency. You can see that the results are very straightforward measurements. When applied with the other calculations we’ll talk about in the next GemaGram, they’ll add up to give you the best possible, and most consistent powder coating, this side of the Pecos River!
Coming in the April GemaGram… The importance of proper Gun Mover Speed and how to calculate it.

“Our ITW Gema upgrade has resulted in savings of $15,000 a month in powder alone!”

THE COMPANY
Allan Industrial Coatings, located in Allison, Iowa, is the Midwest's premier coating job shop. Allan was founded in 1979 by Dave and Monte Allan, who still participate in management of the company along with current owner, Steve Hayes. Currently operating out of two facilities in Allison, Iowa, one facility houses sandblasting and liquid coating operations, while the other 60,000 sq. ft. facility is dedicated to their powder coating operations. These facilities can accommodate small parts up to some of the largest parts in the industry, including products such as agricultural and recreational equipment, store fixtures, and computer components.

THE CHALLENGE
Although Allan received a quality finish with their ITW Gema Easy Series™ manual powder guns, they realized the need to upgrade to an automated system that would enable them to grow their business and meet customer demands. Allan wanted equipment that would reduce powder usage, increase production throughput, increase film thickness consistency, while still maintaining a high quality finish and reducing costs.

THE SOLUTION
Equipment capabilities, turnaround time, and the best value solution were major factors in choosing ITW Gema. Allan decided on the Magic Cylinder® booth, OptiGun™ automatic powder guns, and OptiTronic Plus™ Control units. Two OptiFlex™ Manual Wall Units were also installed for touch-up work.

THE SAVINGS
As a result of the upgrade, Allan increased their productivity, reduced powder usage, improved film thickness consistency, lowered rejects, as well as overall operating costs. "With the savings we are recognizing, the upgrade will pay for itself in one year." stated Brian Fecht, Plant Manager.

Click here to view the entire Allan Industrial Coatings case study!

To find out more, visit:
ITW Gema's
OptiMove

Product Spotlight:
ITW Gema's OptiMove™
Reciprocator Control Unit

The technologically advanced OptiMove Reciprocator Control Unit allows precise control of gun positioning and movement, providing optimal powder coating coverage of any product.

The OptiMove is designed exclusively for operating an ITW Gema Reciprocator and a Positioner Unit, within a powder coating booth system. Like all ITW Gema equipment, the controller is simple and intuitive to use, and features a touch pad interface for reliability and minimal maintenance. Digital readout displays provide accurate at-a-glance information.

Merely enter the results of your gun calculations and you’re on your way to more consistent and higher quality powder coating. The OptiMove is capable of handling up to 255 reciprocating programs, providing maximum flexibility in gun positioning and movement to accommodate any product coating situation.

The OptiMove is designed to integrate seamlessly with OptiFlex™ Automatic Gun and PLC control systems. All this combines to give you ultimate control over your powder coating operation!

For more information on the OptiMove or other
quality powder coating products from ITW Gema,
call 1-800-628-0601, email us at powdersales@itwgema.com
or visit www.itwgema.us.

Does your company
need to optimize?
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• 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?

Call 800-628-0601
and ask for a
FREE
Optimization Assessment
of your powder coating operation,
or visit
www.itwgema.us/upgrade

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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