The GEMA OptiFlex Pro is the latest advancement in powder coating application technology. In this video, Eddie Rhodes, Air Power Account Manager in Tennessee, walks you through the new Gema OptiFlex Pro powder coating handgun, the controller and explains the first-ever power gun with powerboost that provides 110 kV and 110 microamps application support.
https://www.airpower-usa.com/wp-content/uploads/2020/03/demo_thumb.png6521162Airpowerhttps://www.airpower-usa.com/wp-content/uploads/2018/06/Logo_AirPower-white.pngAirpower2020-03-20 14:47:372020-03-20 14:55:37Gema OptiFlex Pro Virtual Demo
While visiting the Carlisle facilities, our team got to see a live demonstration of the Ransburg Turbo Disk Rotary Atomizer. The Turbo Disk is a high-speed applicator with superior atomization capabilities to handle even the most difficult coatings. We’d like to Thank Carlisle Fluid Technologies for having us!
Manufacturing facilities in today’s competitive market strive to produce the highest quality product. In this case study we will discuss the importance of recognizing every company’s desire to produce a premier product with the highest first place transfer efficiency.
A Custom Fabricator, producing products for the truck & and Bus industry
In order to distinguish them within the marketplace, the current manufacturing process needed to meet customer’s mil specs. Their current Powder Units were not producing enough Mils per MFG spec with a Quality finish. Examination by quality control engineers revealed that they were getting back ionization and orange peel when applying more powder and second coats. They determined that each operator had different settings and too much powder output. In addition they did not understand current and voltage and how they relate to a quality finish and high transfer efficiency.
In partnership with the customer, Air Power implemented an Gema OptiFlex 2 manual powder unit. The unit comes with 3 presets: 1: Flat Parts, 2: Recess/complex parts and 3: Recoat mode. In addition these cannot be changed by the operator and allowed ease of use with a simple repeatable process. The Patented Digital Valve control allowed for consistent precise powder output, powder savings, and reproducible coating results.
Currently, the customer is meeting their mil spec and producing repeatable results and has increased there transfer efficiently that has provided a 1 year Return on equipment investment.
Rodney Benfield understands finishing and over the past 31 years at Air Power has learned many skills of the trade. One known fact is you cannot be successful if not prepared. Air Power’s Electrostatic Demo Kits allow for just that – being prepared – anyplace, anytime, anywhere.
“These kits are handy” stated Rodney whom has spent a large portion of his time at Air Power focusing on the finishing industry within the Southeast. “This demo kits stays in my truck and I can deploy it whenever necessary”.
The Air Power Electrostatic Demo Kits contain everything necessary for a successful Graco electrostatic demo including a wide array of nozzles and air caps. Rodney further specified that “even for existing electrostatic customers, taking in the entire demo kit makes sense. It allows us to mix/match newly released accessories to optimize the customer’s process and electrostatic experience”
All of Air Power’s finishing specialist have electrostatic demo kits ready to deploy at a moment’s notice. “Air Power’s primary focus” stated Rodney “is the Southeast and Mexico but, we will go wherever the customer needs us”.
The Air Power Sales team attended Graco’s 2019 Finishing Series Launch Event. It was held at the Georgia Power Center in Atlanta, GA and GEMA’s Training Facility located in Indianapolis, IN. This exclusive training is designed around Graco’s extensive product and application knowledge further equipping our team of Account Managers and supporting Application Specialist’s ability to support, promote, and identify opportunities within the manufacturing community. We were able to receive 10 hours of hands-on training directly with Graco’s team of product managers, engineers, and marketing leaders; allowing for a successful and mutually beneficial event. This training centered around cutting edge technology and product enhancements; with topics including: product messages, combating competition in the field, and proven examples (case studies) of how these technologies solve customer challenges. Below are the seven (7) topics that the Air Power and Graco team covered in detail.
Intelligent Paint Kitchen for Pneumatic Pumps
Graco’s intelligent paint kitchen is a system of smart sensors communicating with each other that optimize the performance of your circulation system. It is a less complex, less expensive alternative to advanced remote monitoring and control for the entire paint room — especially when compared to traditional custom built systems. All components are standard products, not a custom-built system, which makes them easy to be configured and install. And because both the initial investment and installation costs are lower, you’re able to be more competitive in a global market. With the intelligent paint kitchen, you can remotely monitor and control key circulation system parameters like pressures, flow rates, tank levels and agitator speeds. The enhanced awareness of key circulation system parameters in real-time enables quick diagnosis of issues and ensures your system is operating at peak efficiency.
Graco took their trademark, high performing electrostatic spray guns and made them better. They are smaller, lighter and designed to maximize your profits. Available in 40, 60 and 85 kV, the Pro Xp electrostatic spray gun also has a round spray option for when you need a bell-shaped pattern and a High Conductivity version for when you have low resistivity material.
Graco’s sealed lower not only has longer maintenance cycles, but it is also easier, faster and cheaper to replace than an entire pump assembly. The lower is completely sealed, so it can be used for every pumping application in your mix room, including catalyzed coatings. Common components make it simpler to maintain your pump, and it reduces inventory level on repair parts. Plus our positive displacement piston pumps displace fluid in both directions of the stroke, providing low cycle rates and high flow, ideal for applications using shear-sensitive materials.
Graco surge suppressors were designed specifically for the finishing industry from decades of pump technology research. The streamlined fluid path ensures low shear, smooth fluid flow, and superior flush ability.
Graco’s ProDispense is a cost effective, user-friendly electronic system that gives you the capability to quickly and accurately fill cavities with industrial fluids in assembly line environments. The ProDispense allows for Consistent fluid dispense that is compatible with manual or automatic applications. The easy to use interface allows for the tracking of volume. The fluid panel configurations allow for a wide range of material viscosity and flow rates with accuracy ranges of 1 to 3 percent.
Graco’s ProControl 1KE allows you to actively manage fluid and air pressure to lock in precise spray parameters. It not only monitors fluids, it has added controls to manage fluids and improve spray performance. These systems allow for precise control of pressure, flow rates, and atomizing air with the ability to easily adjust. The user interface allows for accurate reporting of material usage while remotely monitoring all fluids via the advanced web interface on your corporate network.
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The new generation of OptiFlex Pro manual units impresses with additional application performance due to the outstanding PowerBoost technology. With OptiFlex Pro, you easily process all powder types and coat complex parts in superior quality – all this worldwide and in the most difficult industrial environments. The use of the Electrostatic App is your first step into Smart Factory Automation and makes the manual coating process transparent.
Maximum Coating Performance
The first choice in manual powder coating
The OptiFlex Pro manual units are uncompromisingly and agilely designed for maximum industrial suitability and worldwide use. The intelligent and durable components fit perfectly together and form the powerful package for superior manual powder coating. The ergonomic and intuitive operation enables every user to achieve the best coating results at any time.
Safe technology for more power performance
The newly developed PowerBoost technology of the OptiFlex Pro series offers with the 110kV the highest powder charging capacity in the powder coating industry while complying with safety regulations. The operator benefits from an outstanding coating performance. The new feature completes the proven high-voltage functionalities, such as PCC mode, presettings an individual coating programs and extends the application range significantly.
highest industrial suitability
– The new OptiSelect Pro gun features a particularly robust and durable design. The ergonomic and light-weight gun is well-balanced in the hand, has a good grip and enables you to coat efficiently and faster.
– The new PowerBoost high-performance technology charges all types of powder even more efficiently. The benefits of the additional power provide higher productivity, faster conveying speeds and maximum area performance.
– The integrated remote control allows easily to activate the PowerBoost powder charging mode and to regulate the powder output right away.
– The integrated cleaning of the powder conveying components can be enhanced by the optional PowerClean module, which ensures a faster and efficient cleaning. This improves performance when processing difficult powders and facilitates colour change.
– The latest generation of nozzles ensures an excellent powder distribution and penetration.
Best Application Results
Be one step ahead of the competition!
With OptiFlex Pro you coat extremely efficiently and with consistently high quality.
The PCC (Precise Charge Control) mode regulates the spray current even in the lowest ampere ranges (0-10µA) with the highest accuracy. This prevents overcharging of even the most demanding powders such as metallic powder and ensures the highest quality in thick film and multi-layer applications and recess areas.
The DVC (Digital Valve Control) technology allows an exact and repeatable adjustment of the powder output and ensures an uniform layer thickness.
for repeatable quality
The new OptiFlow injector with cartridge design further optimises the venturi principle in terms of transport efficiency and low wear. By simply exchanging the one-piece cartridge, the injector performance is optimally maintained. The usage of fewer parts and the seamless design of the injector improves the ability for fast color changes.
Main features OptiFlow injector:
-Cartridge design merges injector nozzle and conveying insert into a single component
– Powder outputs of up to 450 g/min achievable depending upon hose length and diameter
– Quick release design for the powder hose
– Unique Inline-Design
– Cartridge sleeve manufactured from high quality non stick materials
– Robust diecast injector housing
– Quick disconnect air connections
If your production requires frequent and quick color changes, then we would recommend the OptiFlex Pro B, which is designed to use the manufacturer’s original powder box.
– Highest flexibility
– Shortest and cleanest color changes
– For direct transport from the original powder box
– Complete emptying of the powder box thanks to the tilted vibrating base
– Integrated fluidization
– Scratch resistant and easy accessible box plate
Are super-fast colour changes your priority? OptiFlex Pro Q is equipped with additional features that allow:
– Super-fast colour change in 30-40 seconds
– Suitable for all types of powder
– Minimal space usage
If continuous use of the same powder over a long period of time is the bulk of your production schedule, then we would recommend the OptiFlex Pro F with the 50-litre fluidized powder container.
– Ideal for large powder quantities
– Compatible with all powder types
– Scratch-free 50 litre powder container with fluidization
– Easy cleaning of the container
Do you need to economically process powders with a tendency to separation during fluidization? OptiFlex Pro S is your best choice!
– Unique stirrer system with 18 litre hopper capacity
– Processing of powders with poor fluidization capability
– Preventing the separation of powders
– Processing of small quantities without any loss
– Complete emptying of remaining powder
OptiFlex Pro C
For Lab use
Do you want to coat small batches or samples? Your solution is the OptiFlex Pro C with self-fluidizing application cup.
– Perfectly suited for small powder quantities
– Self-fluidizing application cup (optionally 150 ml or 500 ml)
– Processes powder quantities from 20 g to 250 g
– The application cup can be easily combined with every coating unit
OptiFlex Pro L
For small batches
Do you carry out lab applications or quality tests? The OptiFlex Pro L unit is the perfect solution for lab use and quality control.
– Fluidized powder hopper
– 4 litre hopper volume
– Removable powder hopper
– Easy cleaning
OptiFlex Pro W
The universal solution
For upgrades, to be mounted on booth walls or at your production site: OptiFlex Pro W can be integrated in any existing surrounding.
– Its bracket can be mounted on any powder booth
– Takes the powder from fluidized hoppers or original powder box
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The new RansFlex RFXW Direct Charge Waterborne Electrostatic applicator is compatible with waterborne-based materials. The RansFlex RFQ Quick Fan Adjust Electrostatic applicator features the new quick trigger technology that allows the gun to go from a full spray to a round spray with the touch of a button. These new advanced electrostatic finishing applicators feature DeVilbiss® atomization technology.
The RansFlex Electrostatic Low Pressure Manual Applicators are powered by a turbine with a patented design that provides an extra level of protection, which prevents turbine contamination resulting in a more durable product. The ergonomic design provides a balanced and lightweight feel for reduced operator fatigue. DeVilbiss’ world renowned air cap atomization technology is coupled with Ransburg’s electrostatic power to provide superior atomization, transfer efficiency and performance, all backed by a 5-year limited warranty.
The RansFlex Quick Fan Adjust applicator, is an air atomizing electrostatic applicator powered by an onboard generator that provides best in class atomization in a lightweight, user friendly applicator. The RFQ and RFQX both offer superior finish quality surpasses competitor’s larger, higher voltage applicators in small compact size.
The new “Quick Fan Adjust” button allows operators to easily go from a large to a small fan pattern by simply depressing the button located on the side of the gun. this new feature allows the operator to keep the line moving, increasing production.
RansFlex Direct Charge Waterborne and Quick Fan Adjust Manual Spray Gun Highlights:
Lightweight applicator-provides operator comfort and easy maneuverability.
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Instead of using a spray booth to paint their products, they use exhaust plenum. Most colors used are enamel solvent based and the products painted are made up of 50% expanded steel, which is difficult to coat and very time consuming. The HVLP non electrostatic spray gun they were using produced a large amount of overspray.
Air Power Solution
Air Power Inc. introduced the Ransburg RansFlex 45kV, an electrostatic spray gun with much less overspray. The 45kV is better on expanded metal and less faraday cage resistance.
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Graco Liquid vs Electrostatic Spray Gun for Waterborne Paint
Welcome to Air Power’s Finishing Lab! In this video we show the capabilities of the Graco Electrostatic Spray Gun for Waterborne paints. The electrostatic feature can be switched on and off making this spray gun versatile to fit any customers needs.
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