Dawn Denby, Author at Production Systems | High Point NC

Powder Coating. Steps To A Perfect Finish

Powder coating is a process that adds an attractive durable coating to metal. In this process, a dry powder fuses to a metal surface using an electric charge. The metal with the coating is then baked in a curing oven. The result is a smooth hard coating that is tougher than conventional paint. Paint has a liquid carrier, whereas powder coating does not. For that reason, powder coating be applied more thickly since there’s no risk of running. This makes it possible to produce a thicker coating than paint. Powder coating delivers a solid consistent color finish that’s extremely beautiful. Powder coating creates a strong layer that protects from scratching, chipping, fading, and corroding. Powder coating is a durable long-lasting finish for all types of metal. In addition, once the set-up is completed and the necessary equipment is purchased, the process is very economical. Steps To Powder Coating: Powder coating is a multi-step finishing process. Step 1: The metal part is cleaned and prepared for coating. Step 2: The part’s surface is completely coated with a fine powder. Step 3: [...]

Dawn Denby2023-06-20T12:27:45-04:00February 7th, 2023|Powder Booths|Comments Off

Heating Sources For Industrial Ovens

When it comes to industrial ovens, the first two things to consider are the source of the heat and the airflow pattern. The fuel for the heat that’s introduced into the oven can come from a variety of sources including gas, steam, water, electricity, or ultraviolet light. The fuel an oven uses dictates how it works. Gas Ovens There are two types of gas ovens, direct and indirect. In a direct gas oven, a gas or propane burner heats the air that is circulated through the system using a fan. They generally operate at temperatures between 200° F and 500° F, but can reach up to 1000° F. Indirect gas ovens use a gas or propane heat exchanger. A circulating fan pushes air through the heat exchanger to radiation tubes. With this format, the flame is enclosed within a sealed combustion chamber away from the work area. The flame never touches the circulating air. Steam Ovens With a steam oven, water is heated to the boiling point; the resulting steam is used to heat the oven. This is a slower [...]

Dawn Denby2023-01-03T14:38:54-05:00January 3rd, 2023|Industrial Ovens|Comments Off

Recirculating Paint Booth Versus Conventional Paint Booths

To understand a recirculating paint spray booth, we must first consider the conventional paint booth and its process of operation. In a conventional paint booth, air makes only one pass through the system and no air is recirculated. Conventional spray booths have an exhaust fan that draws air through the work chamber, across the part being painted, through an air cleaning apparatus (dry filter or water scrubber) and finally, is exhausted outside the building. In recirculated paint booths the volume of air being moved through the spray area of the paint booth is often the same as with a conventional booth. However, instead of all air being exhausted, a portion is looped back to the booth air supply. A side stream of the recirculation loop is drawn off and exhausted. Fresh air is supplied to the recirculation loop at the booth supply plenum to offset the amount of air being exhausted. The benefits of a recirculating paint booth are substantial. These types of paint booths require less heating and cooling, provide accurate control of climate and airflow, while also providing [...]

Dawn Denby2023-08-01T09:37:51-04:00January 3rd, 2023|Spray Booths|Comments Off

Industrial Ovens – What Types Are Available?

Industrial ovens are used to cure coatings, condition metals, and treat parts using high temperatures. Most ovens fall under one of two categories – batch or continuous. Batch ovens treat large quantities of products at one time and come in sizes ranging from a few cubic feet to several cubic meters. They are manufactured in benchtop versions for smaller products and walk in versions for large scale production. They are generally heated by direct or indirect electrical elements or burners. Continuous ovens, also known as conveyor ovens are part of a mass production system that are continuously fed products. They are designed to fit into a specific manufacturing process that includes a conveyor system. Continuous ovens are used for a variety of purposes including drying, curing, bonding, forming, and more. They may have multiple heating and/or cooling zones. What Are The Different Types Of Industrial Ovens? Industrial ovens come in endless varieties and new ones are constantly being designed to meet specific needs. However, below are the most widely manufactured and used industrial ovens. Curing ovens, also known as baking [...]

Dawn Denby2022-12-06T12:37:07-05:00December 6th, 2022|Industrial Ovens|Comments Off

Levels of Automation in Finishing Systems

Automated finishing systems enhance the quality of the finished products by consistently providing the same finishing touches to each component of your product line. These systems are used by all major coating technologies, including liquid, powder, electrocoat, anodizing, and plating. Increasingly, finishing systems are being built with expanded automation capabilities. This automation creates greater efficiency, flexibility, and scalability, making operations smoother and more cost effective. There are basically 5 levels of automation with regards to Automated Finishing Systems: Most conveyorized finishing systems are at the hardwired control level. This level provides very little automation, and these systems tend to be older models. They are notoriously built to be very robust and durable but offer very little flexibility due to the lack of automation. The first level of automation begins at the Mimic Pane level. This level provides a small level of automation and most of the troubleshooting can be performed by most electricians. It still requires a great deal of operator intervention. This type of automated finishing system is uncommon due to the cost to design and build it. At [...]

Dawn Denby2022-12-06T12:46:48-05:00December 6th, 2022|Finishing Systems|Comments Off

Air Flow Options In Paint Spray Booths Provide Various Advantages And Disadvantages

When it comes to air flow in a paint spray booth, the idea is to move air around the object being painted out of the area, so that overspray does not get deposited back onto the new coating. Advantages and disadvantages of various types of drafting systems result from the direction of the air. Since the air must flow from one end of the booth to the other, it stands to reason that in some instances dry overspray will end up on an area that has not yet been painted, or even worse, an area that has. A good painter knows how to work within the parameters provided by the system to provide a flawless finish, however, it takes effort. Turbulent Airflow Some types of booths create turbulent airflow. Turbulence is created when two banks of air turn and collide with each other on their way to the other side of the booth. This happens again when the air has to separate in two to be exhausted. Turning Air In booth styles, air comes into the booth and must turn [...]

Dawn Denby2023-08-01T09:35:24-04:00November 1st, 2022|Design & Engineering, Spray Booths|Comments Off

Production Systems Provides Finishing System To Gat Creek

Speaking to Manufacturing Today, Gat Caperton, President of Gat Creek, shared his interesting and impressive story about how he started his furniture manufacturing business. Gat Creek, now 26 years old with $25 million in sales and 165 employees, creates residential home furnishings built from Appalachian hardwoods. In the article, Caperton spoke about his ethos regarding the use of sustainable, locally harvested hardwoods and his work with The Conservation Fund, where he learned about protecting the forest. As a wood furniture maker located in Berkley Springs, the geographical center of the Appalachian Forest, Caperton is proud of the fact that there are more trees there now than at any time in the past 100 years. Also a source of pride for Caperton is the fact that domestic manufacturing is experiencing a revival and companies have reshaped the way they make products. Technology has changed the way Gat Creek manufactures furniture. It’s no longer an assembly line approach; artisans have their own work bench where they work on one to five pieces of furniture a day. When this person is finished, they [...]

Dawn Denby2023-01-03T10:24:28-05:00October 18th, 2022|Company News|Comments Off

Pressurized vs Non-Pressurized Paint Spray Booths

Paint spray booths come in various types and styles. Certain kinds are better suited for specific applications. And the opposite is also the same – some configurations are simply not well suited for certain applications. Choosing the right type of spray booth for your finishing business is one the most important decisions you can make. Purchasing the wrong kind of booth can create problems and hinder production. One feature to consider is whether the industrial spray paint booth is pressurized or non-pressurized. The purpose of a spray booth is to move air past the object being painted so that the part is well coated and the overspray does not get deposited back on the object or the newly coated element. Let’s take a look at these two options. Pressurized Booths A pressurized paint booth is designed to work with negative and positive air pressure. The booth operates with a balance of air coming in and air going out; in other words, the balance between the air replacement fan and the exhaust fan. If only the exhaust fan is running, [...]

Dawn Denby2023-06-20T13:22:49-04:00October 4th, 2022|Spray Booths|Comments Off

Three Advancements For Paint Spray Booths In The Automotive Industry

Car manufacturers and repair shops are asking for new features and capabilities to be incorporated into their spray paint booths. Below are some of the most commonly-requested elements from companies who use spray booths. Bigger Is Better. Companies in the automotive industry are wanting larger spray booth designs. What was once a standard-length size – 24 ft, is now increasing to 28 - 30 ft. This larger sized booth allows for oversized vehicles to be accommodated or for multiple treatments to be accomplished in each cycle. Standard height has been 9 ft; that is now becoming 12 ft. But the size of the booth itself is not the only aspect of the booth that is getting bigger. Companies want larger doors and windows, and more glass panels. Larger doors mean wider openings that make it easier and quicker to load and unload the booth. Bigger windows and glass paneled doors and walls allow for improved visual inspection of the process. More Automated Controls Manufacturers and automotive paint companies are more and more interested in more complex control systems that allow [...]

Dawn Denby2024-05-13T14:22:11-04:00September 6th, 2022|Spray Booths|Comments Off

Consider Oven Systems Early In The Paint Booth Purchase Cycle To Save Money

It is important to carefully consider what heating system will be needed before making a paint booth purchase. There are various factors that should be considered in order to make sure a wise investment is made. Consider the following when purchasing a paint booth and oven system: An oven often requires alterations to the plant’s infrastructure. Understanding the requirements can keep you from wasting money in the long run. The exhaust system from the oven may need to be routed through the facility and may require a considerable amount of floorspace. In some instances, installing a heating system may require major modifications and can be quite expensive; for example, adding heating to a cross air-flow booth. Some booths, such as vertical air flow booths, are more easily modified to add heating; however, exhausting it may require a more complex route due to its rear evacuation and need for additional duct work. This may end up being more expensive. If you decide to purchase an unheated booth with the thought of adding heat down the road, make sure to leave space [...]

Dawn Denby2022-08-02T13:06:13-04:00August 2nd, 2022|Industrial Ovens|Comments Off

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