- Higher First Pass Transfer Efficiency
- Better Uniformity
- High Finish Quality
Category Archives: SAMES
Recently, EXEL North America (Manufacturer of Kremlin Rexson) partnered with their local Solution & Service Center, SOT Abrasives and Equipment located in San Antonio, Texas to help an automotive customer create a solution that would finish interior plastic parts for a new division that had moved to the area.
Toyoda Gosei located in San Antonio, Texas is the interior components division of Toyota and they were looking for a solution that would finish the interior plastic parts of their Tundra and Tacoma model trucks. The problem was, this facility had never finished these plastic parts with a waterborne material so it was a new process for them.
EXEL North America and SOT Abrasives & Equipment were asked to come into the facility and offer expert advice on how to spray with a waterborne coating while delivering a fine finish with less overspray. Toyoda Gosei needed a proven solution to be installed very quickly and that is what EXEL North America and SOT delivered.
Toyoda Gosei currently has a Fanuc Robot application and their previous equipment consisted of solvent based product diaphragm pump and HVLP applications. Toyoda Gosei needed a high-efficiency system compatible with their new 1K Waterborne composite paint and they needed it installed very quickly!
Bud Slover and Phil Baker of SOT and Tom Dean with EXEL North America met with the Toyoda team that consisted of Simon Barcena, Jorge Cortes, and John Castillo to discuss the solution and action plan. They agreed upon an installation date, the order was placed, and shipped immediately for delivery.
The following equipment was quoted and installed:
(1) AVX Automatic Airmix® gun on the end of a Fanuc Robot
(2) Flowmax® Pumps – (1) for the waterborne material and (1) for flushing
(1) CTM – Color Change Valve (Paint – Flush)
(1) Circulation Valve
Several Fluid Pressure Regulators
(1) Customized stand for the Kremlin Rexson equipment
Within 15 days from quoting the job, the equipment was installed. After the equipment was installed, product trials went off perfectly! Within the first hour of trials, the parts were ready for production vehicles. This was a very fast implementation and installation by EXEL North America, SOT Abrasives and Equipment and the team at Toyoda. It only took two days to program and integrate the Kremlin Rexson equipment with the Fanuc Robot.
EXEL North America and SOT Abrasives and Equipment was able to provide Toyoda Gosei a system that delivered a fine finish with a much lower overspray than any other finishing application in their facility. We will continue to work with Toyota to help them improve their processes and save them money in the long run!
This is just one of many successes for our SSC network and EXEL North America. To learn more about the Kremlin Rexson product line, please visit our website at:
For more information or questions about this great success story, please email us at email@example.com or email the Solution & Service center, SOT Abrasives & Equipment at: firstname.lastname@example.org.
View more success stories like these at: http://www.kremlinrexson-sames.com/en/usa/infos/103-success_stories.html
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 Cyclomix™ Micro 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 email@example.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!
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.
During my morning cup of coffee I was thinking about why more and more manufacturers have been choosing EXEL North America and our products (Kremlin Rexson, Sames, and Johnstone). I even was thinking, why did I choose this company from the options of companies I could work for. And then I thought of the definition of the word.
Option (op•tion) ˈäp-shən
1. An Act of Choosing
2. The right to choose
3. Something that may be chosen
4. An offensive football play in which a back may choose whether to pass or run with the ball
I like the first two definitions because it makes me think of manufacturers out there that sometimes feel tied to the equipment that they have on their floor. One company we recently starting doing business with had Graco on their floor because they felt Graco was the only REAL option to consider for spray guns and pumps.
And then they met us – A one stop shopping experience. We could do the engineering required for sizing their paint kitchen correctly, make sure the robotic painters were positioned properly in the booth, dial in the settings of their paint applicators and 2K Gear pumps, and even work with their paint supplier to adjust the paint formulation to give them the best quality and finish on their products. There’s about 20 other things we did for them as well, but who likes to brag anyways.
Bottom line, we’re a great option if you might not engineering resources that have extensive paint finishing, coating, and dispense experience. We’re a great option if you want one company to handle everything from the paint kitchen to the spray gun/bell tip.
Am I selling our capabilities pretty heavily? Sure. It’s my job to do so.
Nevertheless, I just wanted you to know that you’ve got options – even if you feel like you don’t have any that are worth a hill of beans. And if you’re looking for the 4th definition of “option,” ok, we’ll be a running back too.
Manufacturing plants are trying lean up and “six sigma” the heck out of every single process in their plant. When it comes to dispensing sealants and adhesives, whether it’s LASD or a wood sealer for kitchen cabinets, EXEL North America and Johnstone Dispense Systems have got you covered. I really don’t want to say the cliché “We sell you solutions.” But I just did. It’s true though. We work with material suppliers to develop new high viscosity products and the application methods to dispense sealants and adhesives FASTER, BETTER, and MORE ACCURATELY. How big is our lab exactly? It’s BIG.
Come by and see us to talk about a dispensing application you want to improve. Or start with just an email to firstname.lastname@example.org.
New Steel Barrel Paint Production System by EXEL North America with Kremlin Rexson Paint Spray Equipment
See the new high transfer efficiency, automatic spray gun system for painting steel barrels.
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)
- 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?
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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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 @
We shipped out our robotic PVC underbody system for SIA today. This was a project that took a lot of hard work to win and a team effort to get out the door. It represents a number of things for us: the growth of our group, the strength of our team, and the open and bright future that lies ahead. This project was a first for us. Not because it was the first project with robotics that we had done before (we’ve done many of those). And not just because it was the first Johnstone turn-key dispense system we’ve done (although I’m proud of that too). To me, this was the first system that a lot of our new team members have had a hand in. It was a new system birthed by talent and ingenuity and partnership. We made sure each component was a good as it could be. We upgraded some components because it was the right thing to do. And we stayed in communication with customer the whole way through. Yes, those are things that any company should do. All companies say that they do those things, few actually do it. I’m proud to be on a team that has picked up great talent and that walks the talk, and actually delivers excellence.
Cheers! To our first system out the door. Truly the first of many more to come with our new and ever growing and expanding squad.