Tag Archives: painting

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

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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