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Get Fast Color Changes in the Time it Takes to Read This!
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Sports Equipment Manufacturer Scores Big with an Upgrade to Quick Color Change Equipment from ITW Gema®!
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Product Spotlight:
ITW Gema's NEW Magic Center® Powder Management System with OptiSpeeder® Technology!
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Free Optimization Assessment.

Find out how your
company can
Achieve Quick Color Changes and Reduce Labor Costs!
Pioneer Manufacturing LLC did!
Click Here.
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Michigan manufacturer saw a 75% reduction in paint line labor costs and increased throughput by 15%, after upgrading to faster color changes!

You're in Fast Company if Your Company Needs Fast Color Changes!

In today’s economic climate, companies look for ways to operate better, faster and smarter. One way to compete is to offer customers a wider color palette to choose from while still maintaining high quality finishes and quick deliveries. Companies are concerned about keeping costs low, so finishing tools must not only offer quick color change, but also need to provide reduced powder usage, less downtime, less labor and fewer rejects.

Any powder coater that makes multiple color changes daily would be interested in quick color change applications. And every aspect of a powder coating system can contribute to, or inhibit, fast color changes. So what does a powder coater need to get fast color changes? Here are a few ways to speed up the color change process.

Focus on Transfer Efficiency: The goal is to keep as much powder in process as possible, eliminating overspray, therefore preventing powder buildup. This attention to transfer efficiency saves on non-productive time spent cleaning during color changes. Click here for more information on increasing your transfer efficiency with ITW Gema’s OptiFlex® series. Use a dedicated hopper, pump, and powder hose for each color. Replace powder hose with ITW Gema’s POE powder hose material (resists impact fusion and facilitates color changes). For Manual Gun Users: Use a vibrating table in place of a fluidized hopper (i.e. OptiFlex-1B) and spray directly from the manufacturer’s box. For OptiFlex Manual Gun Users: Train operators to use the purge feature to quickly clean the powder path (see operation manual for instructions). For Automatic Applications: Consider using a Color Management System, such as ITW Gema’s Chameleon™ or “New” Magic Center®, for quick color changes on your powder coating line. These systems automate much of the color change process and streamline cleaning. Automation within the system speeds color changes by internally cleaning the suction tubes, pumps, powder hoses and spray guns, freeing operators to complete other aspects of the cleaning process. For High Volume Production Lines: Consider a quick color change solution like ITW Gema’s Magic Series™ booths for color changes in 10 minutes or less. Cleaning procedures are simplified and operators do not need to enter the booth. Downdraft technology and a patented airflow extraction feature in the booth’s floor keeps powder in process. Consider a Spray-to-Waste Application: Typical color changes can be accomplished in 20 to 60 seconds (both manual & automatic).

Yesterday, powder coating color change was measured in hours. Today, ITW Gema has evolved powder finishing to the point where it’s now less labor and time intensive to change colors. This means powder coaters are now capable of achieving color changeovers in minutes, and in some case, even seconds… giving you the edge you need to stay competitive and profitable!

Learn how to get Quick Color Changes for Your Powder Coating System by contacting ITW Gema at
(800) 628-0601 or visit www.itwgema.us

"Before the upgrade, we could offer our customers any color they wanted–as long as it was black. Now we have the fast color change capability to provide a wide variety of colors. "

Kyle Camp,
Pioneer Manufacturing, LLC

“Now that we've upgraded to ITW Gema, we have the color change flexibility to grow our business.”

THE COMPANY
Pioneer Manufacturing LLC manufactures metal products for the Rogers Group in Clare, Michigan. Among the companies under the Pioneer corporate umbrella is StageRight, a distributor of major event staging and seating risers, and Rogers Athletic, which produces a full line of football practice equipment and athletic training tools.

THE CHALLENGE
Previously, color changeovers took four to six hours with two operators. Color cross-contamination was a major issue, so the only realistic solution was limiting production to one color. Pioneer wanted to automate their manual system, increase productivity and expand their line to provide a variety of color and finish options.

THE SOLUTION
Pioneer attended an industry trade show looking for quick color change technology. After investigating what the competition had to offer, Pioneer decided ITW Gema and the Magic Cylinder® booth, was the best solution. An OptiSystem™, including OptiGun® automatic powder guns and OptiTronic Plus™ control units, was installed, along with two EasySystem™ touch-up units.

THE SAVINGS
As a result of their upgrade, Pioneer reduced finishing labor by more than 75%, while achieving extremely quick color changeovers. "With one operator, we can do a complete color change in 3 minutes if we spray-to-waste and 5 to 10 minutes if we reclaim," stated Kyle Camp, Plant Manager. "This system has really exceeded all of our expectations!"

Click here to view the entire Pioneer Manufacturing LLC
case study!

We introduced you to ITW Gema's NEW Magic Center® Color Management System in the last edition of the GemaGram, and those who attended Coating 2008 this year had the chance to see the Magic Center up close.

What makes the Magic Center the best color management system available for powder coating is its heart...
the OptiSpeeder®. The OptiSpeeder combines the powder feed and cleaning functions into one compact unit. The OptiSpeeder uses OptiFlow® pumps to convey powder to the guns. Its improved fluidization and low maintenance pumps deliver powder to the guns using less compressed air. This results in a softer powder cloud for improved transfer efficiency. During the Magic Center's automated cleaning, the OptiSpeeder empties the remaining powder for reuse, and purges the pumps and all of the powder hoses... quickly and efficiently. And dustless too, because the OptiSpeeder is a completely sealed and closed system. Because of the "one-button cleaning operation" efficiency of the Magic Center and the OptiSpeeder, one operator can complete a total color change in 10 minutes or less!

The Magic Center Powder Management System is a complement to ITW Gema's Magic Cylinder® and Magic Compact® powder coating booths. All powder coating system controls are integrated into the Magic Center's compact design, making it the ideal color management solution. The Magic Center is easily integrated into any booth or plant configuration, whether automatic, pre-coating, touch-up stations or any combination.
Almost any solution is possible!

Learn how to get Quick Color Changes for Your Powder Coating System, by contacting ITW Gema at (800) 628-0601 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?

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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

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