Category Archives: Electrostatics

Kremlin Rexson Cyclomix™ Micro & EOS Pump Reduces Labor Costs & Increases Productivity for Major Kitchen Cabinet Manufacturer

EXEL North America worked with Olympic Kitchen, one of the largest kitchen cabinet manufacturers in the Greater Toronto area in Ontario, Canada, to reduce their labor and increase  production.  They have been a Kremlin Rexson customer for over 16 years. 

Olympic Kitchens discovered that their 2k materials were not being manually mixed properly. Therefore, they were looking to reduce labor time and simplify the process.  Their application consisted of an automatic  flat-line with a three-circuit Venjakob machine.

Olympic Kitchens offers custom finished kitchens with catalyzed materials.   They are currently using a 2K primer, colors, lacquer, and 1K sealer.  As part of their production process, they needed to make sure that the catalyst was being mixed properly.  Their existing equipment consisted of the Kremlin Rexson 16-120 pumps, Manual Airmix® & Airspray technology, and ATX guns for the flatline machine.

EXEL North America met with Olympic Kitchens and explained the advantages and benefits of upgrading their current Kremlin Rexson equipment to newly, innovative equipment that would reduce their need for manual labor and increase productivity in their facility.

To optimize Olympic Kitchens performance, EXEL North America was able to show how the CyclomixMicro would enable them to have a more precise control in mixing fresh 2k material  when they needed it.  This equipment also delivered timed flushing sequences and volume control.  EXEL North America installed the following Kremlin Rexson equipment into their facility:

  • Cyclomix™ Micro PH 3 + 1
  • 5 + 1 Color kit
  • (1) 20-25F PH for the catalyst
  • (2) 16-120F Kremlin Rexson Pumps
  • (2) 5 Gallon Agitators with lids
  • (3) 55 Gallon Agitators with lids
  • (1) 15c-25 EOS Pump for solvent
  • Airmix® regulators & filters for outbound pressures

EXEL North America was able to analyze their current situation and offer a more suitable solution that would deliver a better “Return on Investment” and reduce their labor costs.

Now, they have a 6-12 month ROI based on less personnel needed to manually mix the 2K materials.  There is no need to re-paint or touch-up because the material is now properly catalyzed.   Finally, the dedicated pumps for the (5) 2k colors deliver a quicker color change with increased productivity.

For more information or questions, please email us at exelnasolutions@exel-na.com or call us in the US at 1.800.573.5554 or in Canada at 1.800.450.0655. For product literature and brochures, please visit our website at www.exel-na.com.

Let EXEL North America help you increase your ROI today!  Give us a call!

Olympic Kitchen Cyclomix Micro PH 3+1 System

Olympic Kitchen Cyclomix Micro PH 3+1 System

Olympic Kitchens Pumping Systems

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Kremlin Rexson Airmix® Equipment used for Vertical Cabinet Finishing Systems

The Kremlin Rexson Vertical Cabinet Finishing System is designed to automatically finish ran­dom shaped parts conveyed on an overhead monorail conveyor though on a vertical finishing line.  The system will automatically finish parts with a back-to-back finishing system for stains and glazes, sealers and top coats.

  • The face and edges of the doors and frames will be uniformly coated
  • The system will be easy to control
  • The system can be designed to run at speeds up to 20 fpm conveyor speeds (Speeds in excess on 20 fpm need to be tested)
  • The sealer/top coat will be uniformly applied with little, if any, manual touch up, even with shaker profile area doors
  • The incoming doors and face frames can be any length; however, are limited to a 48” vertical window. They can be hung in any elevation within the 48” window
  • The Parts ID system will automatically identify the incoming parts and only spray the parts

This system will provide a uniform controlled film build while at the same time generate an A.T.E. (Applica­tion Transfer Efficiency) in the range of 65%. The system is operator friendly.  The uniformity of the film build will be controlled by the system, and not the operators’ ability.

The guns will only trigger when the parts are present. Vertical systems are designed to apply a controlled film build on the door, drawer fronts and face frames, and all edges. The system is designed to avoid coating the backs of face frames which will improve the glue areas.

The system provides a RFV2000 two-meter reciprocator at each of the two sealer/top coat spray  frames, will be automatically detected as they pass through the part ID
identification system. When the parts enter in the finishing area, the AVX Airmix® guns, will coat the front face of the part, and the two remaining edges. This combination will pro­vide uniform coverage. Because the coatings tend to dry to fast for wet-on-wet edge coverage, each of the four edges must be finished completely in one booth.

Control System

The Control System will be controlled by our PLC driven System Controller.  The System Controller will control the two RFV2000 reciprocators and all 10 or 12 Airmix® spray guns. The controller will monitor the conveyor speed and part movement. When the conveyor is on and parts are entering the booth, the System Controller will trigger the guns as required to uniformly coat the parts. When he conveyor is shut off, the controls will automatically turn the spray guns ff. When the conveyor is restarted, the guns will resume their programmed
finishing.

The system will read in the part profile as the part travels through a curtain. This profile will be stored in the PLC and transferred down line to the two opposing reciprocators. One reciprocator will be used to paint the front of the part and the other will paint the back of the part. The gun positions will be preset and each gun will have a specific task. An encoder
will be used to track the conveyor movement. The recipro­cator will be a continuous chain type and will be capable of running at speeds up to 350 fpm.  The  system will setup to track this high-speed reciprocator. Two intrinsically safe sensors will be supplied for each re­ciprocator. One sensor will be used to determine the home position of the reciprocator.  The other sensor will be used to track the incremental pulses of the reciprocator as it travels back and forth.

AVX Airmix®

The heart of the system is the Airmix® application system.   Airmix® provides paint application controls that are unmatched. These include:

Forward Velocity Controlled to 2 fps

Other systems are four to five fps and higher. The more con­trolled the forward velocity is the less paint bounces off the substrate which results in
higher transfer efficiency rates.

Controlled Paint Distribution in the Fan Pattern

Airmix® provides uniform paint distribution from the edge of the pattern to its middle. Other systems provide a heavy center, which leads to overlap problems.

Controlled Particle Size Distribution

Airmix® produces a uniform atomized particle size. Other systems have a large size particle range which makes high transfer rates very difficult. Additionally, the controlled range
helps minimize color contamination problems when striping or with different colored heads.

Excellent Equipment UpTime

With the field-replaceable Delrin seat insert and the self-wear adjusting Rulon fluid cartridge, equipment up time is “second to none” in the industry.

For more information or questions, please email us at exelnasolutions@exel-na.com  or call us at 1.800.573.5554.  For product literature and brochures, please visit our website at www.exel-na.com

Kremlin Rexson Equipment Reduces Coating Waste for Major Kitchen Cabinet Manufacturer

EXEL North America partnered with one of the largest kitchen cabinet manufacturers in North America to reduce their coating wastes and improve finish consistency.  Due to production requirements, all 2K coatings needed to be accurately and freshly mixed with no down time during color change. This required a large quantity of 2K mixing machines to be installed at each spray booth.

The kitchen cabinet manufacturer’s application consists of hand spraying cabinets on an overhead conveyor.  They were using a hand mixing method and needed to improve their process as there was considerable paint waste and inconsistencies in the mix quality.  They are applying an acid catalyzed clear coat and pigmented base coats.  These coatings needed to be ready to spray at all times during production hours without any problems.  EXEL North America was able to eliminate the hand mixing process and improve the finish quality.

EXEL North America analyzed the process and offered a more suitable solution that would provide a better “Return on Investment” and reduce coating wastes.

To optimize the kitchen cabinet manufacturer’s performance and reduce their coating wastes, EXEL North America installed the following equipment into their facility:

  • (70+) Cyclomix™ Micro pH Machines
  • (100+) Airmix® fluid regulators
  • (10+) 20-220FPH and 20-25FPH catalyst pumps
  • (100+) Xcite® guns

EXEL North America was able to help the kitchen cabinet manufacturer reduce coating usage and waste and eliminate the manual labor associated with hand mixing.  For pigmented coatings, they expect an ROI within 12-15 months.  On clear coatings, they expect an ROI of 24-30 months.

EXEL NA is currently quoting additional 2K equipment for a few more of their locations.  We hope to continue to optimize their performance and reduce their coating waste by showing them the best options available by using the equipment that Kremlin Rexson manufactures.

The customer is so pleased with the performance of the Kremlin Rexson equipment that they have standardized this process at various locations throughout North America.

Kremlin Rexson is the world’s leading manufacturer of complete plural component equipment solutions for acid catalyzed coating applications.

For more information or questions, please email us at exelnasolutions@exel-na.com or call us at 1.800.573.5554.   For product literature and brochures, please visit our website at www.exel-na.com.

Kremlin Rexson Equipment

Kremlin Rexson Creates Paint and Labor Savings for Hydraulic Cylinder Manufacturer

EXEL North America worked with Monarch Industries located in Winnipeg, Canada to reduce their Work-In-Process Time  (WIP).   Monarch’s goal was to be the best manufacturer of hydraulic cylinders.

Monarch Industries application consisted of automatic hydraulic cylinder finishing with an overhead monorail conveyor system.  They were using manual Graco Electrostatic equipment and running three shifts with approximately 10 people per shift.  Monarch was producing 2000 cylinders per day  with varying batch sizes while each cylinder needed to be primed and top coated.  The primer was a one color 2k epoxy, and the top coat was a 2k urethane in various colors.

EXEL North America was able to analyze their current situation and offer a more suitable solution that would offer a better Return on Investment.  To optimize Monarch’s performance, create a long-term paint savings, and reduce the amount of labor, EXEL North America installed the following Kremlin Rexson equipment in Monarch’s facility:

  • 04-120 and 04-220 Flowmax® circulation pumping systems
  • AD-60 Paint Heaters
  • 55 Gallon Agitator and cover lifts
  • Two Cyclomix™ Experts for Primer (one manual and one auto)
  • Two Cyclomix™ Experts for Top Coat (one manual and one automatic)
  • Two Spraymium™ Primer Electrostatic spray guns for primer touch up
  • Two Spraymium™ Top Coat Electrostatic spray guns for top coat touchup
  • Primer automatic application system, RFV2400 dual axis reciprocator following system
    with three PPH308’s
  • Top Coat automatic application system with RFV2400 dual axis reciprocator following
    system with three PPH308

One of the reasons this was a success was because the RFV2400 system allowed us to only spray on the apex of the cylinders, which provided a much higher Transfer Efficiency rate than previous systems.  The system allows for rapid color change with fresh urethane at all times and we were able to control  the process with an RFID control system.

EXEL North America was able to help Monarch Industries save on their painting costs.  The paint costs went from $1.50 per average  cylinder down to $1.00 per cylinder.   With the new system in place, all cylinders are finished during one shift while the old system required three shifts with 10 people on each  shift.  In addition to paint costs savings, we were able to create a labor savings of approximately 20 people.

For more information or questions, please email us at exelnasolutions@exel-na.com or call  us at 1.800.573.5554.  For product  and brochures, please visit our website at www.kremlinrexson-sames.com

Monarch Industries New System

EXEL North America is pleased to announce the release of the New Kremlin Rexson EOS Pump Range!

EXEL North America is pleased to announce the release of the New Kremlin Rexson EOS Pump Range!

Kremlin Rexson has set the standard again for medium pressure solutions.  We are introducing the new EOS Pump Range with two pumps: 15-C25 and 30-C25. The New EOS Pump “Accelerates Performance” by delivering  Efficiency, Optimization, and Simplicity through its advancements in design, operation, and easier maintenance procedures.

The innovative design and quality components provide reliable performance and allow for simple maintenance, easy cleaning, and fast color changes while using minimal solvents.  The cost of ownership and operation is reduced to a minimum.

To lean more about this innovative line of pumps, please visit our website at: http://www.kremlinrexson-sames.com/en/usa/news/139-new_kremlin_rexson_eos_pump_range.html

You may also view our launching video at: http://www.youtube.com/watch?v=JfhGOw2FKtk

You may also contact EXEL North America at 800.573.5554 or email our marketing team at exelnasolutions@exel-na.com

Contact us today to learn how you can get your new EOS Pump!

EOS 15-C25

EOS 15-C25 Pump

EXEL North America Announces….. NESHAP 6H – Paint Rule Compliance

On January 9, 2008, the EPA accepted a new standard known as the HAPs 6H rule to reduce the public’s health exposure to Hazardous Air Pollutants (HAPs). The agency’s main objective is to significantly lessen the amount of HAPs released into the environment during paint stripping or surface coating operations.

During such work practices, the most dangerous chemicals, namely, methylene chloride (MeCl), cadmium, chromium, lead, manganese and nickel compounds, represent significant risk to employee health if proper engineering and administrative controls are not in place.

Because the requirements are extensive, the EPA is allowing existing facilities until January 11, 2011 to reach compliance. 

At EXEL North America, we have gathered information about the 6H Paint Rule and would like to share it with you.  For more information and a free copy of this document, please visit us at:

 http://www.kremlinrexson-sames.com/fichiers/Literature/English/2010_Kremlin_Rexson_6H_Paint_Rule_Brochure_web.pdf

http://www.youtube.com/watch?v=qFscqbMZ3kI

If you have any questions, please email us at exelnasolutions@exel-na.com or call us at 800.573.5554.

EXEL North America Beats out Binks & Graco in the Energy Market

EXEL North America has been successful working with customers whom specialize in manufacturing Mobile Drilling Rigs within the Energy market.

EXEL North America, in partnership with their local Solution and Service Center, EAH Austin Inc. located in Texas, worked with Loadcraft to replace their Binks and Graco spray finishing equipment.  EXEL North America was able to develop a solution using our innovative  2K Cyclomix™ Expert System with  Gun Flush boxes, and Dual controls to finish (spray paint) their mobile oil drilling rigs.

With the help of EAH Austin Inc., EXEL North America was able to provide Loadcraft with a 30%+ material cost savings of their material consumption.  Previously, they lost $100,000.00 in wasted mixed materials due to their manual mixing process.    VOCs were reduced, the quality of the finish was improved due to atomization used by Airmix technology for the primer and topcoat, and Loadcraft increased their production by reducing cycle time to create additional thru parts.

The Sales advantages for the customer were that EXEL North America and EAH were able to supply a system that can manage (2) spray booths with one Cyclomix™ Expert for the Primer and one for the Top Coat (Dual booth controls).  We were also able to include the Dual Gun Management system as each booth has (2) guns per material ((2) for Primer and (2) for Top Coat).  These features weren’t offered by our competitors.

For more information or questions, please email us at exelnasolutions@exel-na.com or email the Solution & Service center, EAH Austin Inc. at:  mike@eahequpment.com.

View more success stories like these at:   http://www.kremlinrexson-sames.com/en/usa/infos/103-success_stories.html

 

 

 

 

 

 

 

 

 

 

 

 

How to do an Effective Electrostatic Demo

I found this oldie but goodie article from the archives on how to do electrostatic demonstrations.  This is one of those pieces of advice that still holds true today and never goes out of style….. I don’t know who wrote it.  But I do know they work for us!

“….While doing electrostatic demos in the past, I frequently asked the customer how my competitor did during his demo. I usually heard very bad comments like:

• His equipment didn’t work!

• Black stuff came out of his pump!

• He didn’t have the right gun!

• His nozzle was wrong!

In general, my competitor just wasn’t prepared! Was I glad that wasn’t me because I would never do a demo that unprepared! Now it was my opportunity to show the customer my “stuff”. I started to carry my demo equipment into the plant (three trips to my car).

Assembly took me almost 30 minutes and of course, I was missing an air hose. I asked the customer for quick disconnect fitting and another 15 minutes went by. The real problem came when I asked the customer for a 5 gallon bucket (clean, of course). He found a bucket that was currently used as a trash can and made an attempt to scrape it clean. Another half hour. Obviously, the customer was not impressed, as we were not spraying paint yet.

Finally 1½ hours later, we have the paint in the system but for some reason it s not wrapping and I find out that the black paint has carbon in it and it is shorting out the electrostatics. On the way back to the office, I am very discouraged and frustrated. Then it dawns on me – “I am my competitor”. I just made the same mistakes that I was laughing at him for doing. I thought could never be that stupid. Boy, it was a long ride back to the office.

During this drive, I started to think. I don’t have to worry about my competition. “I am my competition.” I lost this sale by myself. It was totally my fault as the term “the easiest way to lose a sale is to do a demo” entered my mind.

Then I started to get mad at myself. How could I be so stupid? What can I do so this never happens again? My brain went into the “deep thought” process. “Yes, I do believe I can plan so that this doesn’t happen again and my close ratio on sales will certainly go up as I can then be in control of the situation.”

This is what I decided I must do:

1. All equipment must be cart mounted.

2. All equipment must be assembled – all hoses, fittings, etc. This eliminates any chance of leaving things at the shop.

I must bring with me:

  • Five Gallon bucket with line
  • One gallon cans (new)
  • Rags
  • Solvent for cleaning (one gallon)
  • Zahn cup or Afnor 4 cur
  • Stop Watch
  • Quick disconnect fittings (6 stems will cover most customers)
  • Cart must have an air blow gun (non safety) or a ball valve for quick easy tip cleaning
  • Solvent for conductivity adjustment
  • Paint Meter
  • Anything else?

Yes, this sounds like I have everything and I’ll really be organized and prepared, but what about that “black” hot paint?

Continue reading

How Does an Electrostatic Paint Sprayer Work?

Ever rub a balloon against yourself and make it stick to a wall or other object? That is the basic idea of how an electrostatic paint sprayer works. The rubbing of the balloon causes it to obtain more free electrons, which makes a negative charge. The negatively charged balloon now will stick to neutral or positive objects.  Ken Eyestone is our training manager at Exel North America, Inc.  And according to him, electrostatic paint sprayers are the way to go to save paint, money and the environment.

Paint Sprayer

  • At the tip of the paint sprayer is a small electrode, which creates high voltage electricity. As the paint particles travel at a slow speed through this corona of electricity, they become negatively charged.

Paint Surface

  • The paint surface is the grounded, positively charged surface, which has a magnetic attraction to the negatively charged paint. As you spray the paint, the paint overspray may initially travel off in a different direction, but will turn back to the positively charged object and stick to it. The paint will stick to any surface that is conductive. Metal definitely. Wood has water in it, and the wetter the wood, the greater the positive charge. Surfaces that include plastic, stucco and wood that are old and very dry will need a thin coat of conductive adhesive promoter applied before painting.

Paint

  • Electrostatic paint sprayers work well with an oil- or water-based paint. However, water has a stronger positive charge than oil. The paint needs to be able to hold a charge, but not be too conductive. Solvents can be added to paints to make them perfectly charged. Contact the manufacturer of the paint to see what, if anything needs to be added to the paint. The size and velocity of the paint particles is also important. The smaller the particle mass, the greater the attraction. The slower the particle, the greater the effect of the paint charge.

Benefits

  • The benefit of using an electrostatic paint sprayer is in the saving of paint. Expect to use 25 percent to 50 percent less paint. In a big job, that is a lot of paint and money saved. There is less waste which is good for the environment. There is very little overspray to clean, and the paint coverage also has a very nice, smooth look.

Drawbacks

  • If you have sharp edges, the paint will go on much thinker. The particles of paint are very attracted to corners and sharp edges. Where you have an inside corner, the paint goes on much thinner, if at all. This is called the Faraday Cage Effect. The solution to this problem is when spraying into a corner, the painter paints with electrostatics that are turned off for that part.

Warning

  • If the surface to be painted is not grounded, the charged paint particles will search for the nearest ground. This will in all likelihood be the painter!

See a Bell Atomizer in Action from our lab demonstrations @

http://www.youtube.com/exelnorthamerica or you can find literature at http://www.exel-na.com

Read more: How Does an Electrostatic Paint Sprayer Work? | eHow.com http://www.ehow.com/about_6322236_electrostatic-paint-sprayer-work_.html#ixzz0sXDXeVhZ