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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


EAH Equipment Success with Painting Trailers and Drilling Rigs with Kremlin Rexson Equipment

Products Finishing did an article on the success story by the Kremlin Rexson distributor, EAH Equipment (Austin, TX).

Loadcraft switches to new paint system for drilling rigs.

When part-time oilman Terry McIver went to Brady, TX in 2004 to buy a used drilling rig, he was surprised to find the company he was visiting was going bankrupt. Brady left with the oil rig, but a few months later he went back and bought the company.
Article From: Products Finishing, Tim Pennington, Editor
Posted on: 4/1/2011

Loadcraft builds and paints trailers and rigs that must have a durable coat in often harsh weather conditions.

When part-time oilman Terry McIver went to Brady, TX in 2004 to buy a used drilling rig, he was surprised to find the company he was visiting was going bankrupt and had just two employees left from over 200 it had a year earlier.

Brady left with the oil rig, but a few months later he went back and bought the company.  Today, Loadcraft is booming as it designs and manufactures trailers and drilling rigs, some of which can cost $9 million.

But with a watchful eye on the economy and the mood swings of the oil industry, Loadcraft’s manufacturing department sought a better, more economical way to paint its trailers and rigs than what they had been doing.

“We wanted to get away from mixing everything by hand,” says Tim Perry, Loadcraft’s paint manager. “Let’s say there was a lot of human error involved.”

For example, they were using a zinc rich epoxy primer and a urethane topcoat on its mobile drilling rigs, but often saw much of the paint go to waste because of the hand mixing.

“It wasn’t efficient to mix six gallons and have two gallons left over that went to scrap,” Perry says. “We thought it would take that much, but you just never know.”

Loadcraft had been using an airless spray system, but after examining several different options settled on Kremlin Rexson Cyclomix system (manufactured by EXEL North America) that automatically mixes the paint and reduces excess waste.

EXEL North America rep Tom Dean at EAH Equipment (Austin, TX) helped install a system for two spray booths for the primer and topcoat, as well as a dual gun management system for a pair of spray guns in each booth.

Dean says the new set-up cuts down Loadcraft’s waste by more than 30%, and estimates the savings to the company at about $100,000 annually.

“Loadcraft had calculated their wa based on the mixed material that was left over from hand mixing,” he says. “They were also spraying with conventional and airless application equipment. We also have the ability now to record actual usage on A side, B side and solvent material being sprayed. We have no left over mixed material besides what is in the hoses to be flushed.”

The Kremlin Rexson Cyclomix Expert can manage up to 24 components (bases, catalysts, flushing solvents), and can handle mono, bi- or tri-component materials. The machine is programmed on a color screen with ratio/tolerance data assist management to monitor material consumptions.

By properly handling the mix, Loadcraft also reduced its VOC output, Dean says.

“We also reduced the solvent flush cycles,” he says. “They now use 50 feet of ¼-inch hose versus large high-pressure pumps and pressure pots that required a large amount of solvent.”

Loadcraft opted for automatic flush boxes which are located in the spraying area, close to the painter so that it enables the person to be hands free while system is flushing.

Perry says having the system programmed to run according to designated specifications is a time saver, as well as a money saver.

“To have it all tied back into a computer is really helpful,” he says. “We had to learn the little tips and tricks to get it set up right, but it went very smoothly.”

Loadcraft specializes in design and manufacturing of 250-2000 horsepower drilling and work over rigs, as well as trailers, dollies, beams, and multi-axle components to support the heavy haul and oilfield transportation industries.

Since McIver brought the company out of bankruptcy, the facilities have expanded to include everything from a machine shop, three weld production lines, an on-site testing area, a vast warehouse and an indoor assembly area.

The company’s equipment can be found anywhere from the San Juan Basin in New Mexico to the deserts of Oman. In the past several years, more than 130 rigs and close to 900 trailers have been shipped to Argentina, Columbia, Kuwait, Chad, Egypt, Turkey, Mexico, Libya, Venezuela, India, Ecuador, Russia, Turkmenistan, Belarus, Kazakhstan and Iran.

That means the paint finish needs to last, especially in 130˚ heat in the Middle East.

“We’ve had good results with the finish so far,” Perry says.

Dean says he can see a better finish with his company’s Kremlin Rexson Airmix Atomization system than the old method Loadcraft was using with airless and conventional spray.

“With airless, the high pressure method would create a dull overall finish due to the lower atomization characteristics of airless spray,” he says. “The Airmix Atomization delivers the material at a very low velocity of 2 ft/sec versus 4 ft/sec with airless and 30 ft/sec with conventional.”

Dean says the Airmix uses a specially designed aircap to provide a smooth and even finish.

“The aircap helps to evenly atomize the paint as it leaves the fluid tip,” he says. “The even atomization allows the paint to be broken down into smaller particles, which provides the best coat with minimal defects or orange peel.”

For more information on EXEL North America products, please call 800-573-5554 or visit www.kremlinrexson-sames.com