Holiday Wishes from Thierica Equipment Co.

Another year draws to an end. Peace on Earth is still a dream rather than a reality. I guess “Peace on Earth” is something inside us instead of something outside of us. As we celebrate Christmas, it is my prayer that all of us would know that true inner peace, that the Child would live in us at this holiday time and throughout our lives. So good bye to 2006 and here’s to 2007. May this be the year that we all find real peace and joy. Thank you for your business. We hope 2007 is rewarding and safe for you and your family. God bless you.

How To Compete In This Economy

2007 is looking at moderate growth in the industrial markets. Well, moderate grow is better than no growth, but how do you continue to expand your company in this economy? “Process”, improve your process. So much waste is generated in the finishing department. This waste leads to high costs and added pollution. Constant evaluation and improvement is the most cost effective way to compete in this new global market place. Thierica Equipment Co. is once again offering a Process/System evaluation free of charge. We will send a sales engineer, with process experience, for the purpose of evaluating your process and system. We will look for ways to reduce cost, improve quality, reduce pollution, and generally improve your bottom line. Let us help you compete in 2007. Contact us at (616) 453-6570.

Save Money With 2K Material Handling Systems

Many customers are still “hot potting” their 2K materials. This is a very expensive way to handle two component paints and adhesives, and can lead to inaccurate mixes and rejects. There are several manufacturers who have developed systems to mix the material, track application usages, and save many times the cost of the equipment and it’s integration. Each manufacturer has their own approach to 2K mixing. Graco is the leader in “dosing” systems which are strong with low flow rates. They have a wide offering from one gun, hand spray, applications to multiple, automatic and robotic systems. ITW Ransburg features two very different technologies with “real time” mixing with their DynaFlow flowmeter system and their “gear pump” system, RCS 2. RCS 2 is a very dependable, accurate system. Ransburg also offers everything from low cost, one gun systems, to high end multiple automatic and robotic systems. 2K mixing systems give you consistent, accurate, mix ratios, and eliminate expensive waste at the end of the shift. You need to consider upgrading your system with this money saving solution. Thierica Equipment Co. has a cost justification form that can help you to decide if 2K equipment is cost effective for you. Just ask us.

Gast Mfg. Contracts Thierica For Green Belt Project

by Dave Kooienga, Thierica Sales Engineer 

Overview: Due to previous success of merging a green belt project with a Value Stream effort, Jay Zimmerman (New Product Development Engineer, Gast) was challenged to achieve a similar result for his green belt certification project within Gast’s second Value Stream. The success of the Air Motor Value Stream depended on better paint adhesion to reduce the disruption of manufacturing flow that reworking paint caused. His initial inquiries into possible alternative coatings brought UV (Ultra Violet) paint to the forefront of discussion. Its remarkable ability to cure very rapidly, as well as its phenomenal hardness and adhesion immediately drew attention to UV paint as a possible solution. Subsequently, and with the help of Dan Apotheker (Manufacturing Engineer, Gast) and Dave Kooienga (Thierica Equipment company), a design and layout were drawn up to coincide with the testing and other validations that were being performed. After the initial design stage and actual implementation, it was found that the new process saved 850 square feet and reduced the production lead time from 4.5 hours to less than 15 minutes. In addition, WIP (Work In Process) was reduced from 190 to 12 pcs, an amazing 94%! The Science of UV Paint, in brief UV paint can best be thought of as liquid plastic. This liquid will never evaporate, and will never harden under normal conditions; but when it is subjected to intense UV light, molecules of liquid bond with other molecules to form very, very long chains. The end result is a very hard, durable and chemically resistant coating known as polyester acrylate. This transition can happen in less than 2 seconds on flat surfaces, at the optimal distance from the light source. At Gast, the shape of an air motor prevented such a quick cure time. During the “Analyze Phase” of the green belt project, the engineers experimented with several options and concluded that rotating the part in front of a UV bulb for 30 seconds would insure proper curing, and allow the cell to produce one painted and cured unit every 75 seconds; well below the required TAKT time of 90 seconds. Benefits and Drawbacks: The primary benefit of the new system is the reduction of lead time. Within the first two weeks of implementation a customer needed an expedited order of 50 air motors --- they sent a courier to pick them up only three hours after the raw material came to receiving. This would have never been possible with traditional paints. Other benefits include the dramatic reduction of Volatile Organic Compounds (VOCs). The VOC emissions into the environment from the Air Motor Value Stream were reduced to negligible amounts, along with the complete elimination of the noxious solvent MEK, a definite step in the right direction regarding the health of employees. Since implementation on August 14, 2006, even the employees of the Air Motor Value Stream have been impressed with the change. Jay and Dan have frequently heard comments that the air motors “look better,” and “won’t scratch or stick to packaging anymore.” Key Takeaways: The debugging phase of the Air Motor Value Stream is winding down, and the Value Stream implementation could not have been a success without the help of green belt projects like UV Paint. As a result of this synergy, customers will see the increased durability in the product and the increased responsiveness of Gast to emergency orders. Internally, Gast sees a reduction in WIP, and a substantial reduction in value stream process time.

Another Success Story

Galion LLC was founded in 1954 and produces a variety of innovative screw machine parts for automotive and military customers. They came to Thierica Equipment Co. looking to improve quality, reduce costs, increase output, and reduce VOCs. Thierica, working with ITW Ransburg, found a solution that surpassed everyone’s expectations. We were able to apply, in one booth with an AeroBell 33, the same mil requirement as Galion was applying in two booths with HVLP guns. The results took Galion from 2000 parts per gallon to well in excess of 15,000 parts per gallon! The paint is not even visible as the projectiles turn color in front of the bell. Adding to this system’s amazing transfer efficiency is the added control provided by ITW Ransburg’s RCS II flow control and Thierica’s user friendly system controls. The results are greatly reduced paint costs, greatly reduced VOCs, improved product quality, and very nearly a 100% increase in production capability. This is the definition of a win/win situation. Call us to see how we can improve your paint line, your bottom line, and help make you a better neighbor at the same time. Making your company “green” can also make your financial statement “green” as well.

Gun Applications

Guest Writer: John Owed, ITW Ransburg

The object of this paper is to identify and discuss the parameters related to the application equipment, define their relative purpose and discuss methods for controlling, optimizing and/or monitoring them. Once identified, the “normal” operating parameters used for day to day operations of a finishing system can serve as a barometer of the system performance. When given parameter changes, effort should be taken to immediately identify why it changed. 

Atomization Air \ Pattern Air: Atomization Air is the air pressure used to break up a fluid stream into small particles. The atomization air holes on the air cap are holes drilled in the face of the air cap surrounding the center where the fluid exists. 

Pattern (also referred as Horn or Fan) Air is used to shape the atomized particles into a elliptical shape. This elliptical shape is often referred to as the spray pattern. The pattern air exits through the raised portion (horn) or the air cap. 

These terms are generically associated with all types of spray applicators including, manual, automatic, electrostatic, conventional, HVLP and LVMP. The most common mistake made with these types of applicators is the failure to obtain a uniform elliptical spray pattern. All too often the applicator is adjusted by ear or feel. The operator turns up the air pressure until they can’t hear the supervisor or until the gun kicks when the trigger is pulled. 

In the case of a manual application a poorly shaped spray pattern is compensated for by the operator. The operator will make adjustments in their technique based on the visual feed back they receive while spraying. 

With a machine or robot mounted applicator, it is imperative that a uniform spray pattern always be maintained. Since the machine or robot program is made based on a specific spray pattern size and index, a misshapen spray pattern will cause rejects. In effort to obtain optimal results with an air atomized applicator, the atomization air and pattern air must be able to be adjusted independently. 

Testing has proven that in most cases the pattern air pressure should be 5 to 10 psi higher than the atomization air pressure. The following procedure should be used to obtain an optimal spray pattern: 
1. Adjust the fluid flow rate to the volume required to obtain the desired coating thickness. This volume can be calculated based on the surface area, volume solids, desired coating thickness, and approximate transfer efficiency. In the case of an existing system, start at the rate that is presently being used. 
2. Adjust atomization air pressure to the lowest level at which acceptable atomization is obtained. Atomization quality can be visually evaluated by passing a metal test panel through the atomized particles at the proper target distances. Start at 15 psi of air pressure and adjusted in increments of 5 psi. Label the panels and visually compare the size of the atomized particles. Poor atomization is indicatd by large droplets nestled close together. Over atomization will yield very small dry looking particles. With good atomization the particles will have a wet appearance that are some what uniform in size throughout. 
3. Adjust the pattern air by starting at the air pressure setting used for the atomization. Using a sturdy panel (that won’t move) located at the proper target distance (10-14 inches), spray the applicator for several seconds or long enough so that the pattern will sag. The air cap should be positioned so that the pattern is horizontal. 

Because several spray outs are typically required, it is best to cover the panel with pieces of foil that can easily be removed and compared. Examine the spray pattern; look for the paint to sag uniformly along the length. Adjust the pattern air pressure up or down as required in 5- psi increments until a cigar shaped pattern with tapered or blunt edges is obtained. If the spray pattern has the appearance of a “dog Bone”, heavy on the ends and light in the middle, then the pattern air is too high. If the pattern looks like a “football” heavy in the center and light on the ends, then the pattern air is not adjusted high enough. If a teardrop shaped pattern is obtained (heavy on one side only), the air cap should be rotated 180 degrees. If the heavy end switches sides, then there is a good change that some of the air holes in the cap are plugged or damaged. Clean the cap and repeat the test. 

If the heavy end does not move when the air cap is rotated, the fluid tip may be damaged. Inspect the air cap and fluid tip alignment. The fluid tip and air cap should be concentric. If the fluid tip is damaged and touches the air cap, this can block air flow and cause the abnormality. Once a uniform pattern is obtained, the length of it should be measured and documented. 

Although the above procedure appears to look long and drawn out on paper, the actual process can be accomplished in several minutes. To eliminate the need for repeating the above procedure on multiple applicators, test air caps are available. The test cap consists of an air cap fitted with hoses and gauges. They allow the operator to check the air pressure settings directly at the applicator. Once the above settings are documented on the first applicator, the others can be quickly adjusted by using the test cap. The operator should not depend solely on the reading of a gauge at a pneumatic panel. In effort to ensure that all the spray patterns will be the same, the air pressure at the applicators must be checked. The fluid flow rate at each applicator should also be adjusted so that they are all equal. 
If the above procedure is followed, all applicators will have consistent spray patterns. 

Air atomized electrostatic guns are typically mounted on a long stroke reciprocator. A long stroke reciprocator is generally classified as having a stroke of three feet or greater. When adjusting the cycle rate of a long stroke reciprocator the pattern width and conveyor speed must be taken into consideration. There are several overlaps that will produce a uniform film. The two most common and easily calculated are a 50 and 75% overlap. With a 50% overlap, the conveyor advances one pattern width per cycle of the machine (a cycle is made up of two strokes). In effort to calculate a 50% overlap, divide the conveyor speed in inches per minute by the pattern width in inches (the pattern width should be measured using the method outline above). The answer will be the number of cycles per minute the machine should run. Divide this number into 60 to obtain seconds per cycle and adjust the machine with a stopwatch. The maximum speed of the machine should not exceed 240 feet per minute. At speed over this, the pattern of the guns will “broom” and the atomized particles will be redirected. This speed should be checked by multiplying the cycles per minute by the total length of chain in the machine. 

Please note the following example: Example: Calculating a 50% Overlap, assume the following Conveyor Speed: 15 feet x 12 in. = 180 in. Min. 1 ft. Min. Pattern Width: 14 in. Machine Data: Sprocket Centers = 6 ft. Chain Length = 12 ft. Calculating Cycles per Minute: Conveyor Speed in/min = Cycles per minute (cpm) Pattern Width 180 in/min = 12.86 cyc/min 14 in/cycle Calculating chain speed: Cycles per minute x chain length in feet = Chain Speed 12.86 cyc x 14 ft. = 180 ft. min. cyc min. In the above example, the machine speed was calculated at 180 feet per minute. This is an acceptable speed well within the range of an efficient application based on a 50% overlap. With a 75 overlap, the conveyor advances half of the pattern width per cycle. A 75% overlap is obtainable with regards to machine speed is considered more desirable. A 75% overlap can be easily calculated by doubling the numbers calculated in the above example. In the above example the machine speed of 180 ft/min @ a 50% overlap would become 360 ft/min. @ a 75% overlap. This number far exceeds the recommended maximum of 24 ft/min. In this example, a 75% overlap could not be used. 

When the multiple applicators are used on a long stroke reciprocator which is typically the case, this in no way impacts the above calculations. Each applicator should be visualized putting down a uniform coat of material based on the overlap selected. The spacing of the applicators on the traveling gun bar should be such that the patterns do not interfere with each other. If 14 inch spray patterns are used, the applicators should be spaced a minimum of 16 inches apart.

Thierica Equipment At IWF 2006

Thierica Equipment Co. and the Victoria Group are joining forces to provide the best in flat line finishing equipment and systems. This partnership will be featured at the IWF 2006 Woodworking show in Atlanta, GA, August 23 through 26. Victoria will have on display their “Rotomax” flat line machine. Representatives from Victoria and Thierica will be on hand to answer your questions and assist you with any and all of your finishing needs. Please look us up in booth 6617. Hope to see you in Atlanta!

Will Electrostatic Systems Work For Me?

This question is frequently asked of paint systems and equipment suppliers, and, in most cases, the answer is “Yes”. Since Harold Ransburg invented the electrostatic process just after WWII, there has been more than a few refinements and improvements to the process. Today, most plastic parts for automobiles are finished with electrostatic applicators. Non-conductive substrates are made conductive by basically two methods: the application of a prep coat, conductive primer, or conductive adhesion promoter, prior to the electrostatic application; or by the introduction of a conductive “buck” to the part racks. Wood substrates can be finished electrostatically by maintaining 6% moisture content or by the prep coat method. Applying a conductive material prior to the electrostatic application can be done with conventional applicators or, if a prep coat material is used, with a prep coat tunnel. It is important that the racks are conductive and that a good ground is maintained from the rack to the conveyor to ground. The conductive material must also be used to “paint” the part to the rack thus causing the part to be grounded to the rack. Failure to “paint” the part to the rack can greatly reduce transfer efficiency and even create the conditions that could lead to a static build up on the parts with the potential for a discharge of electrostatic energy. Grounding is the key to reaping the benefits of electrostatics’ transfer efficiency while insuring maximum system safety. Metal bucks employ the same concept as a magnet through a piece of paper. When you place a piece of metal on a paper and place a magnet under the paper you can move the metal with the magnet. A similar event occurs when a metal casting of the back of a plastic part is incorporated in to the paint rack for that part. The grounded rack and casting is what attracts the charged paint. The plastic part just “gets in the way”. Most automobile fascias are processed in this manner. The paint cost savings and quality improvements of electrostatic painting are huge. Often the return on investment is in weeks rather than years. Cost savings along with reductions in VOCs make electrostatic painting an ever improving method for finishing your parts. Thierica Equipment Co. has the experience and knowledge to guide you through this decision making process no matter if you are purchasing a new paint system or looking for ways to improve your existing line. All our sales people have “process engineering” experience with companies very much like yours. No one is better suited to help you with your paint finishing needs.

"Quick Change" Spray Guns

Changeable end arm tooling is nothing new in the machining industry, but not many have attempted it in the paint industry. Thierica was challenged by one of it’s customers to change colors between racks without wasting solvent or paint. General Manager, Lou McGough, took on the project and developed what we are calling “Quick Draw Technology”. Not only does Quick Draw allow for fast color change between parts without waste, but you can even spray non-compatible paint chemistries because the fluid contact parts go with the gun. When a gun is not in use, the robot simply “holsters” it in a holder on the booth wall. You could even combine a flush box with the “holstered” gun(s) so you could flush and change color in them while you are spraying another color. The number of guns in the system is really only governed by the number of hoses that are practical in the booth and the robot reach. The sky is the limit when it comes to applications of this new technology. Do you have a use for “Quick Draw”? Or maybe you have another application challenge. Call us. We would be happy to work with you finding solutions to your finishing problems.

Thierica de Mexico Is Newest ITW Automotive/Ransburg Distributor

For some time now, Thierica has had an office and manufacturing plant in Monterey, Mexico, in order to better serve our many customers in that growing market. When ITW Ransburg came looking for a distributor to partner with in Mexico, they were excited by our existing customer base and our experienced workforce already in place. Thierica saw an opportunity to expand our product offering by partnering with the dominate manufacturer of finishing equipment in North America. It’s a win/win for both companies and for the many manufactures who have established plants in Mexico. Contact us for all your finishing needs anywhere in the world. We have the products and capabilities to improve your finishing line and your bottom line.

Get A Complimentary Process/System Evaluation

“You can’t see the forest for the trees.” It’s been said over and over and it is still true today. Sometimes we lose sight of the issues costing us time and money because we are too close to the situation. You see the same system every day. You spend most of your time “putting out fires” rather than finding new and creative ways to improve your process and reduce costs. This is where a “new” set of eyes can be very beneficial. Thierica’s salespeople come from a “process engineering” background. Our salespeople have been where you are. They see things through the eyes of someone who’s “been there, done that.” We understand the pressures and issues you face in the finishing department. With that in mind, Thierica is making the following offer: Let one of our “process engineers” evaluate your system. We will visit your facility, observe and gather information to help us understand your process/system, and then prepare a report with recommendations on how you can improve your quality, reduce your costs, and/or increase your production rates. What’s in it for us? We are confident enough in our abilities and knowledge to offer this service in the hope of gaining your trust and consideration as you look at systems and system upgrades. There is nothing for you to lose and much for you to gain. Call (616) 453-6570 or send an inquiry through our website.

Dominic Zerilli Named Sales Manager

Thierica Equipment Company is pleased to announce the promotion of Dominic Zerilli to the position of Sales Manager. Dominic has been in sales at Thierica for over ten years handling many of the key accounts throughout North America, Central America, South America, and Europe. Dominic has been instrumental in creating Thierica’s ability to offer a variety of creative process solutions for a diverse mix of customer products, a factor that has kept Thierica in the forefront of the systems business in an ever changing world market. Mr. Zerilli’s technical knowledge and value added approach to customer service will maintain and improve Thierica’s leadership role into the future.