Issue link: http://www.e-digitaleditions.com/i/901126
POWDER COATING, November 2017 15 W hen customers initially contact an infrared (IR) supplier to talk about powder coating, they usually have a very real need for a solution to a very real problem. The initial idea can come from many differ- ent directions, perhaps the need for added capacity, or a step change in the level of quality, which is either de- manded by the customer or an internal need to reduce rework and scrap. Occa- sionally, companies have never powder coated products themselves, but always outsourced and now wish to establish better control over the process and their delivery times. Whatever the need, years of experience building systems has shown that the customer always ends up not only solving the original, well-identified, and quantified prob- lems, but also ends up realizing major gains and advantages in areas that they never, ever predicted. Starting the discussion The initial conversation between cus- tomers and suppliers about new powder coating ovens usually revolves around cost and ballpark figures. The unsur- prising conclusion of these initial dis- cussions is that a conventional convec- tion oven will cure powder on parts with a lower capital outlay. As you would expect, though, there is a big "but" attached to this statement. What usually follows is a conversation about how IR typically requires 50 percent less space, uses 50 percent less energy, and cures powder in a third of the time. Then the discussion normally con- verges on two indisputable facts: 1. Convection ovens are often a blunt, but effective, tool that is unsophisticated in operation and expensive to run. 2. IR is a sophisticated, precise process that is highly controllable with a higher capital cost, but much lower running costs. Sometimes, customers are fearful of a technology that they have never used before and unsubstantiated doubts can gain root. However, it is vitally impor- tant to remember that IR is not simply a replacement process for powder coat- ing by convection, but a significantly improved process that is capable of de- livering much more and can have a big impact across the complete manufac- turing system. These unintended con- sequences are not always envisaged by customers, but are very welcome none the less. The ultimate decision to invest in an IR system is most often made after thorough testing. To illustrate the unin- tended consequences of IR, let's take a look at a recent installation that demon- strates the wider impact. A real-world case study Recently, Metsa Inc., Monterrey, Mex- ico, a premier manufacturer of domes- tic propane tanks in North America, ap- proached Heraeus Noblelight with the main goal of increasing production due to US market expansion. Heraeus No- blelight, Buford, Ga., manufactures and supplies natural gas or propane fired industrial catalytic heaters that emit IR heat through a safe, flameless heater technology. There were three underlying issues that needed to be addressed for Metsa to achieve success. First, their existing powder coating process utilized hand applied powder, cured in batch convec- tion ovens, and could not keep up with demand. Second, it was difficult to achieve a consistent cure on the heavier collars and angular feet of the tanks, which are made from a thicker steel sec- tion than the rest of the tank. Third, they had the never-ending drive to re- duce operating costs. IR Curing ShopTalk Infrared Equipment Division of IHEA This column is provided to you by members of the Infrared Equipment Division (IRED) of the Industrial Heating Equipment Association (IHEA). The group includes infrared (IR) curing equipment suppliers from throughout North America. We publish the column three times a year to give you the latest information about IR curing techniques and equipment. Contact information is at the end of the column. Most IR manufacturers offer testing for free or for a fee. Any IRED member can assist you in finding solutions to curing problems and best practices for finishing of coatings. This issue's column was submitted by IRED member Chris Chapman on behalf of Heraeus Noblelight, Buford, Ga. Gas catalytic IR — The unintended consequences