Introducing Ransburg’s New RansFlex Direct Charge Waterborne and Quick Fan Adjust Manual Spray Guns

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.
  • Ergonomic handle design-eliminates operator fatigue.
  • Protected strategic components-divorced turbine air supply cartridge, sealed nozzle/atomization passages and strategic turbine location.
  • DeVilbiss atomization technology-coupled with Ransburg electrostatics.  The best of both worlds.
  • Simultaneous fan and atomization pressure-adjustment with tool adjustable compensation valve.
  • FM tested and approved

 

 

Gas Catalytic Infrared Pre-Gel Oven Improves Production by 16%

The optimal cure time at Gatormade Trailers was not being achieved by the current curing method.  This was most evident on their largest parts as denoted within the oven temperature profile.  Air Power in conjunction with Heraeus discussed the opportunity and determined that a pre-heat booster oven solution could potential eliminate the challenges observed onsite.  Heraeus conducted trials in which proved successful and installation of the provided system was streamlined; minimizing production downtime.  This solution is modular, allowing for future expansion, should GatorMade Trailers process and production rates deem necessary.  Check out the complete Case Study to learn more about pre-heat and booster oven solutions that Air Power has to offer.

Customer

Gatormade Trailers is a company that prides itself on ‘Big Quality, Big Service & Big Value’. Based in Somerset, Kentucky, the company operates from a 300,000 sq ft factory and manufactures a wide range of trailers from small utility up to their 53 ft long Gooseneck trailer. The company has a policy of constant progress and improvement in all aspects of their business to ensure their products always exceed customer expectations.

Challenge

In 2011, Gatormade Trailers stepped up the heat and invested in a custom built, in-house powder coating facility. Consisting of a 70 ft convection oven, running at 600oF (316oC), it helped the company transform the manufacturing side of the business. They now had full measure over their powder coating and curing processes. This provided a perfect waypoint to drive further quality improvements on an already great product. The heaviest part that they put through the oven weighed in at 9000 lbs and measured 53 ft long. To achieve the required quality of finish, they found that the line speed required slowing from 3 fpm to almost a standstill. This was the only way to ensure that the powder flowed correctly and gave a consistent gloss. But, this ‘Big’ slow down in production was not acceptable to a company with ‘Big’ values and a growing order book. They needed to find a way to get their line speed back up to 3 fpm and still maintain a high quality finish.

 

Solution

Gatormade Trailers got in touch with finishing systems integrator, Air Power Manufacturing Solutions (based in High Point NC), who suggested a Pre Gel Gas Catalytic IR oven from Heraeus-Vulcan Catalytic. Heraeus’ engineers came up with a ‘Big’ solution, a giant, 3-section, 36 heater solution! The heating profile of each section is controlled by a PLC control system which enables different profiles to be created and stored for different product sizes. Each program can be called up as required. During production breaks the complete oven can be switched to a ‘low fire’ condition, which reduces the power output to a minimum, but still maintains the ability to ramped up to the desired output within 60 seconds. This is one of the key features of Heraeus’ ovens and helps to reduce the overall energy consumption.

This Gas Catalytic IR pre-gel oven was placed directly in front of the convection oven, together with a 8′ (2.5m) vestibule. The aim of this configuration is to use the natural characteristics of Infrared to raise the temperature of the powder extremely quickly to the point where it starts to gel. Remember, IR is absorbed very quickly by the powder, and does not require the complete part to heated up to the gelling temperature. By the time the part is leaving the pre-gel oven the powder is at the gel stage. The part then enters the convection oven for the final cure. This process now takes considerably less time and uses less energy.

Results

The addition of a Gas Catalytic IR pre-gel oven to the existing convection oven has transformed the finishing line. They have solved the problem of curing powder on the largest parts. The system also works on every part that goes through, which adds further savings. The production increase of 16%, and reduction in energy costs will ensure a very short ‘payback’ period on the investment. This is expected to be around 18 months.

 

 

 

 

Source: https://catalyticovens.com/gatormade-trailers-case-study/

 

 

Choosing Your Powder Equipment Partner

 

Choosing Your Powder Equipment Partner

 

In this video, two of Air Power’s application specialists Travis Stirewalt and Eddie Rhodes discuss the things you need to take into consideration when choosing where to buy your powder coating equipment. Air Power shows our true dedication to supporting the needs of our customer base by not only distributing industrial equipment, but also offering repair services in-house and in the field, engineering services for integrated solutions and over 50 years of industry experience. Contact us today to find out how we can help Powder Coat like a Pro!

1 (800) 334-1001

 

Find us Online:

Facebook: https://www.facebook.com/AirPowerUSA

LinkedIn: https://www.linkedin.com/company/206581

Twitter: @Air_Power_Inc

Can You Color Change Too Fast?

Manufacturing facilities strive to improve the quality of their finish while reducing color changeover time in an effort to produce the most desirable product quickly. In this study we will discuss the importance of recognizing every company’s desire to improve in these areas and how improvements can be made within a custom powder coating operation.

Customer

 

A local wheel remanufacturer and custom coater located within North Carolina.

Challenge

 

This facility was constantly losing valuable production time due to quality rejections.  Once rejected, the part was reworked and coated a second time.  This caused a cumulative effect on both powder usage and man hours proving rework within this facility a high cost and overhead factor.  In addition, the existing manner of color change resulted in the facilities inability to keep up with current workload. Daily operation consisted of: 4 main colors, an occasional “custom” color, and a clear coat.

Air Power’s Solution

 

Air Power proposed a Gema OptiFlex 2 Wall Unit with multiple dedicated fluidizing hoppers.  These fluidizing hoppers are plumbed for the 4 main colors.  A Gema cup gun was provided for the “custom” colors and clear coat. Air Power was able to provide an onsite demo at the customers facility allowing the customer to test, prove, and inspect the proposed solution prior to investment.  The improvement in both quality product output and line throughput was dramatic.  In addition, the facility was impressed with Gema’s five (5) year manufacturer’s warranty and Air Powers local support and service.

 

Result

 

The immediate improvement was first observed within the finish quality which was noticed within the existing customer base.  Due to this improvement, repeat business was observed more readily and additional customers were earned, growing an ever increasing need for a more expansive customer base. Even though workload was increased, production never had to slow down. The quick color change system, with dedicated pump/hose combination, allowed operation to change color quickly removing the former bottleneck.   An added benefit of the system was the removal of pre-heating parts to achieve powder thickness and build.  This result was observed due to Gema’s industry leading transfer efficiency, new found operator control, and recipe programing within the system.

Can you color change too fast?  If you ask this custom coater the answer is no; and their ability to change colors faster with an increase in finish quality has taken the operation to new heights.

 

OptiFlex 2 Wall Unit color change system

 

Gema Gun with Cup for small and test batches

 

 

Batch Powder Systems

Batch Powder Systems offered by Air Power at a competitive price. Financing options available.

Batch Powder Systems offered by Air Power at a competitive price. Financing options available.

 

Air Power can help you select the batch powder system that is right for you. This complete system includes the powder booth, curing oven and powder application equipment. Various booth and oven sizes available.

Batch Powder Systems

 

 

 

Gema OptiStar Operation

 

In this video Air Power’s Powder Specialist Matt Mouzon shows you the ease of operating the Gema OptiStar controller on a Gema Optiflex 2B box feeder. Gema offers simplicity with 3 application presets which automatically control KV and current (µA – microamps) that take all the difficulty out of powder coating. Remember Gema makes it easy to use Any Powder, Any Part, Any Place and is the powder application equipment you need to powder coat like a PRO!  Contact Air Power today to find out how we can help you powder coat like a pro!

Call us at: 1 (800) 334-1001
Email us at: sales@airpower-usa.com
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Gema Gun Tips & Extensions

 

In this video, Air Power’s Powder Specialist Matt Mouzon explains and displays several gun tips and easy part changes for the Gema Optiflex powder gun. In addition to the gun tips, also featured are 2 different sizes of gun extensions for the Gema Optiflex powder guns, which allow for a longer reach for hard to reach parts including pipes and large cabinets. Contact Air Power today for replacement parts, gun extensions, electrodes and nozzles that are perfect for your application. Contact Air Power today to find out how we can help you powder coat like a pro!

Call us at: 1 (800) 334-1001
Email us at: sales@airpower-usa.com
LIKE, SHARE & SUBSCRIBE
FIND US ANYWHERE ONLINE:
FACEBOOK: https://www.facebook.com/AirPowerUSA/
LINKEDIN: https://www.linkedin.com/company/airp…
TWITTER: https://twitter.com/Air_Power_Inc

Powder Coating Series: Gema Accessories – Cup Gun + Lab Unit

 

In this episode of Air Power Live, Travis Stirewalt showcases 2 Gema accessories. The first powder coating gun accessory is the Cup Gun – Optiflex 2C which allows for small custom powder coating application projects. The Optiflex 2C fluidizes a small amount of powder and plugs directly into the gun handle. It is a user friendly project winner. The small 3 lb hopper Optiflex 2L. This allows for small volumes of production powder for fully optimized powder fluidizing. It operates in the exact same way as the Gema 50 lb hopper with a smaller footprint. The Optiflex 2L can be purchased by itself or as a package with an Optistar Controller and Optiflex powder gun. Contact Air Power today to find out how we can help you powder coat like a pro!

Interested in purchasing? Contact Air Power today to find out how you can get your hands on one of these! You can even schedule a LIVE DEMONSTRATION!
Call us at: 1 (800) 334-1001 or
Email: sales@airpower-usa.com or
Find us anywhere online: www.airpower-usa.com

Graco Liquid vs Electrostatic Spray Gun for Waterborne Paint

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.