Vertical Powder Coating Systems for Architectural Aluminum to Begin
Alexandria, AV - The powder coating industry promises to revolutionize the U.S. architectural market, when two new vertical powder coating systems designed for coating aluminum extrusions begin operation in the United States this year.
Following the efficient vertical powder coating operations that have proven successful in Europe and other parts of the world, these new facilities will quicken production and coating time and offer better quality control, for a more economical coating operation. Combined with the environmentally friendly, durable, and energy saving finishing alternative that powder coating provides, these new systems promise to be the first of many new vertical architectural aluminum powder coating lines in North America.
Greg Bocchi, Executive Director of The Powder Coating Institute, remarked, "I am excited that these new vertical extrusion powder coating lines will soon begin operation in the United States, as they will help give powder coating the influence to better penetrate the U.S. architectural market."
The first vertical line is scheduled to begin production in August 2005. Extruders Texas is a division of the Atrium Group, one of the largest producers of aluminum windows in the United States. Trevisan Cometal North America Inc. is installing a complete vertical powder coating line for Extruders Texas in Wylie, Texas.
The system includes an energy efficient, low maintenance pretreatment washer, automatic powder guns along with an automated cleaning delivery system supplied by ITW Gema, automatic synchronization of gun stroke lengths and reciprocator speed, and a fast cleaning cyclone booth and final filters to recirculate and re-use the air. Both large and short batch production profile runs may be powder coated, on one or both sides. The system also utilizes convection ovens with an infrared booster for dry-off and curing. The whole line is maintained by programmable logic controllers with a customized supervision software system.
The line will provide a complete range of standard colors, including metallics, textures, and the new Effecta process which brings the look and feel of real wood to aluminum products.
The Extruders Texas line can accommodate 24 foot parts, with the possibility of many color changes per shift with no production time lost during the color change. Compared to a horizontal line, the Extruders Texas vertical line promises, according to a Trevisan spokesperson, "Better quality and production control, and higher quality of the end product," with "a much higher production and lower cost per unit or lineal foot cost."
The finished product will meet performance specifications set by the American Architectural Manufacturers Association for 1-year, 5-year, and 10-year weatherability, or AAMA 2603, 2604, and 2605.
In the fall of 2005, Indalex of Gainesville, GA, will begin production on its vertical powder coating line, adding powder coating to its current liquid operation to satisfy its existing customer base looking to convert to powder and to open up new powder coating markets. Nordson Corporation is installing the powder operation for Indalex.
The powder system will feature an automatic self-cleaning vertical spray booth with composite canopy construction. The application equipment provides maximum transfer efficiency and includes internally purgeable automatic guns with external blow-off, and an integrated control system with part ID and programmable user presets.
The delivery and recovery systems feature a central feed center and a cyclone and afterfilter recovery system.
The washer, dry-off oven and cure oven are all PLC controlled. The washer features all stainless steel construction, U-Pass design, and quick release nozzles. The cure oven features a passive air seal at the entrance and exit, and includes a gas-fired IR section to help the powder gel quickly and reduce overall cure time.
The line will start out with twelve organic colors initially, with possible expansion to more colors, textures, and metallics in the future.
Part sizes will range from 12 feet to 24 feet vertically hung aluminum extrusions, primarily for window frames, plus door frames and other commercial and residential building components. Indalex plans to operate at a line rate of 24 feet per minute, competitive with line speeds currently achievable with liquid vertical coating lines.
Compared to a horizontal line, vertical powder coating promises "40% more throughput," according to a Nordson spokesperson, and "more flexibility in terms of varied part lengths." He also noted the benefits of powder coating over liquid systems, eliminating volatile organic compounds and the need for thermal oxidizers, less waste with the opportunity to reclaim overspray, and a more durable coating than seen with liquid finishing.
The Indalex vertical powder coating line will meet 1-year, 5-year, and 10-year AAMA 2603, 2604, and 2605 specifications for weatherability and stain resistance.
PCI's Greg Bocchi noted, "Powder coating of architectural products has been slow to develop in North America, even after decades of success in Europe and other parts of the world. With the successful implementation of vertical powder coating lines and many liquid-based vertical aluminum extrusion lines facing more EPA regulations to reduce VOC's, I am hopeful that powder coating may finally come on strong in the North American architectural market."
The Powder Coating Institute represents the North American powder coating industry, made up of suppliers of powder coating materials, equipment, and related products and services, and is committed to serving its members by promoting the benefits of powder coating technology.
SOURCE: The Powder Coating Institute