Your Best Finish Starts With TTX!
Published

Auto or Manual?

We are trying to decide between automatic and manual powder application equipment.

Share

Q. We are trying to decide between automatic and manual powder application equipment. We will be running our new line at 6 fpm. Our product opening will be 36 inches wide × 54 inches high. We have a variety of parts that are of welded construction, some that are fairly simple and many that have more complex shapes. Most of our products cannot be coated with automatic -only spray. The automatic guns are pretty expensive, and we do not know how to calculate the value. Any suggestions? R.D.

 

A. First, look at what each kind of application equipment is best equipped for. Manual applicators have sight and flexible axis of motion. Operators can adjust the gun settings for different applications in a short period of time. They can view the part to cover only what is bare and avoid leaving any light spots.

If the operator is well trained and maintains proper flow rates, the manual gun can provide exceptional transfer efficiency.

Also, manual guns can be cleaned for a new color in a very short period of time.

Automatic application equipment is useful when operators may have trouble keeping up with the amount of surface that has to be covered. Automatic guns provide more precise and repeatable coverage over larger surfaces. Automatic guns take longer to clean unless they are fitted with equipment to blow-down the gun parts automatically.

The first question you need to address is: “Can two manual operators keep up with the amount of surface that has to be covered per minute?” Two sprayers can cover about 45 ft2/min. If your product window were fully loaded at 6 fpm, they would just barely be able to keep up. The line will not be wall-to-wall parts, so it appears that two people can keep up with this line speed. Indeed, there are many manual-only lines operating at 6 fpm. However, the complexity of the parts may have a profound influence on how well they keep up. Also keep in mind that you can go to four manual stations in one booth. It does not appear that you would need that, but it is a viable option for flexible coverage and fast color change.

The value of the automatic guns lies in three primary areas: 

 

1) If the operators cannot keep up and stop the line, the guns are justified.

2) If the reject rate is higher because of light coats, the guns are justified.

3) If absenteeism and worker fatigue are adversely impacted, the guns are justified.

 

 

At 6 fpm, you should consider having a booth that can be fitted with automated guns even if you cannot afford them or don’t need them at this time. If problems arise and the auto guns are needed, they can be added.

Keep in mind that it is often harder to get approval for an additional capital purchase later on. Finally, there is no downside to owning the automatic guns and using them as needed. If you can afford the capital now, that would probably be the best way to go. Also keep in mind that many companies look to speed the line up at some point.

If it were my line I would seriously consider buying the guns now and having a flexible line that can do many things without stressing the applicators.

 

Vitracoat Inc. powder coatings
Keyland Polymer UV Cured Powder Coating
complete finishing application systems
Powder Coating Institute Certification
Your Best Finish Starts With Us!
Steelman Industries Inc.
Powder Coating Institute
The Finishing Industry’s Education and Networking Resource
Heatmax Heaters ad with immersion heaters
New Acid-Free Bright Nickel Process
Metal Pretreatment Technology
PF Podcast

Related Content

economics

Henry Ford Is Still Right When It Comes to Color

Who would have imagined that more than 100 years after his famous statement about any color as long as it’s black would still have relevance of a sort?

Read More
management

Top Shop’s Journey to Building a Unique Brand

Since this new Ohio plater took over the space and assets of a former plating business, it is intentional about setting itself apart from prior ownership.

Read More
Electroplating

Indonesian Plater Finds Fast Success in Auto Market

This father/son team, inspired by inventor Michael Faraday, focuses on anti-corrosion methods and automated processes to help their Indonesian plating business flourish.

Read More
automotive

Robots, AI and Superb BMW Surfaces

There isn’t an automotive paint shop in the world that doesn’t have post-paint inspection and defect processing. But BMW is doing this with levels of technology at a plant in Germany that exceed all other paint shops in the world.

Read More

Read Next

Sponsored

Delivering Increased Benefits to Greenhouse Films

Baystar's Borstar technology is helping customers deliver better, more reliable production methods to greenhouse agriculture.

Read More
Parts Cleaning

Education Bringing Cleaning to Machining

Debuting new speakers and cleaning technology content during this half-day workshop co-located with IMTS 2024.

Read More
Parts Cleaning

A ‘Clean’ Agenda Offers Unique Presentations in Chicago

The 2024 Parts Cleaning Conference, co-located with the International Manufacturing Technology Show, includes presentations by several speakers who are new to the conference and topics that have not been covered in past editions of this event.   

Read More
Industrial Finishing Equipment