Efficient powder coating of geometrically complex components

A manufacturer installed a new coating system in order to be able to coat even complex components efficiently and automatically in all colors with powder coating. This increased production speed and minimized powder consumption.

The family-run company Shoemaker, based in Cle Elum in the US state of Washington, is a pioneer in the production of air outlets and heating registers for both commercial and private facilities. The component color is applied by powder coating. The demands on the coating process are extremely high. The parts are geometrically complex, multi-layered and different metals are used. The white and brown colors were coated in automatic coating booths. All other colors were coated manually.

The ever-increasing demand for parts that are not white or brown presented Shoemaker with ever greater challenges in production. Long color change times and a high proportion of manual work slowed down the production speed immensely. In addition, the results could vary depending on the experience and daily form of the coater. Inadequate powder extraction further reduced process efficiency.

To meet the increased market requirements, Shoemaker decided to optimize the coating process. Shoemaker not only wanted to remain competitive, but also to stay one step ahead of the competition. The requirements were clear. The optimized coating process had to cover the following points: Automatic coating of two standard and eight designer colors with minimum color change time, consistent coating quality, reduction of rework, maximum efficient powder extraction and high production speed.

Several concepts for a new coating solution were viewed and examined in detail. Wagner's concept proved to be the best overall solution. Within 9 months, Wagner built a system that would revolutionize Shoemaker's production.

The white parts are now coated in an automatic booth that has been expanded to include the SprayPackE. The application control system enables central operation of all system components and, thanks to its simple user guidance, is an ideal introduction to automatic series production. The control system can be customized for up to 32 automatic spray guns. Compared to the previous control system, the SprayPackE now ensures a significantly more efficient and resource-saving use of materials while also increasing the coating result.

For all other colors, the Wagner specialists installed an E-Line system including a PXE powder center. This compact system offers an economical entry into automatic powder coating with fast color change. In general, workpieces with a size of up to 2,000 x 800 mm (height x width) can be coated highly efficiently. The powder can be fed from the fluid container or directly from the powder box. High application efficiency, robust surfaces, fast color change times and an intuitive operating unit ensure Shoemaker achieves optimum results under all conditions.

Thanks to the new Wagner powder coating system, Shoemaker is able to automatically coat all parts in all required colors, reduce the number of personnel required for reworking by 90 percent per shift, increase production by up to 30 percent, significantly minimize powder consumption through intelligent powder recovery and reduce colour change times to a minimum. (OM-2/23)