One of the most common questions asked of those in the powder coating industry is whether to use a manual batch-type system or an automated line.
The answer isn't always easy: Batch systems and automated lines use different approaches to powder coating, each with their own advantages.
For those unfamiliar with the terms, an automated system (or automated line) is a powder coating system that moves parts automatically through the various steps of the powder coating process. These steps usually include using a chemical wash to prepare the surface of the parts, drying the parts, applying the powder coating media, curing the powder coated finish onto the parts, then allowing them to cool.
The parts typically move in one direction from device to device, and all tasks are done to different parts simultaneously. A batch system, on the other hand, allows the operator to manually prepare and accumulate parts, then coat and cure the parts in batches. The parts are typically moved from one device to another by hand using carts.
Here are some of the most useful tips for deciding whether a batch or automated system best suits a coater's needs.
If you're dealing with thousands of similarly sized parts per shift, an automated system is probably your best bet. The more varied the shape and size of the parts, the less advantage an automated system typically offers. A batch system provides significant benefits in terms of powder coating equipment cost and workflow versatility, but relies on workers to move parts, prep parts and apply powder coating media. So, if the volume of parts is quite large, the advantages of a batch system are lost.
If the coating process outpaces the manufacturing process, a batch system is ideal. If the powder coating process delays output, an automated system may help. You can coat large quantities of similar items quickly, since parts don't have to be handled between stages. If the automated line is designed for rapid throughput, a constant flow of parts can be coated at a rate that usually can't be matched by manual techniques.
Batch systems generally take up less room, so they're better for businesses that can't spare extra space. Batch systems sometimes use one oven to do the work of both drying and curing parts, which further reduces cost and saves on floor space. By using ovens where the parts move back and forth multiple times inside relatively short but wide enclosures, some automated lines fit into surprisingly tight spaces. But most automated lines involve restricted access to at least some key components, especially in cramped spaces. This drives maintenance and repair costs up.
Batch systems are significantly cheaper than comparable automated lines, usually costing less than half as much, so if your budget is tight it might be best to start with a batch system. Batch equipment requires more manpower, but also tends to have lower maintenance costs. Batch systems can also provide lower operating costs because you only use equipment as it is needed. With automated systems there is almost always a constant process of coating taking place, so relative operating costs can increase if the system is not being used to full capacity.
No matter what type of system is used, have a plan for growth and size your equipment accordingly.
Now that you understand the selection process for a batch powder coating operation, it's time to determine if a batch line or automated coating system is the right solution for your operation.
Are you launching a large coating operation from scratch and can't decide what type of line will work best? Have you been powder coating with batch equipment but need to increase throughput? Perhaps you're bringing powder coating in-house to finish the products your company manufactures, but you're not sure how to do it. The decision to install an automated finishing system is a considerable one. Before you make the investment, you need to ask yourself if an automated system is right for your company's operation style and daily coating requirements.
The number one reason to move from a batch line to an automated coating system is to increase throughput. If your business needs to produce a high volume of powder coated parts on a daily or weekly basis, and these parts are somewhat similar in size, you should consider installing an automated line. Since automated coating is a continual process, you'll almost always be able to coat more parts in a set period of time than if you coated them manually in small batches. But, many problems with throughput can be resolved with less expensive batch equipment.
If you already have a batch system in place, and your production quota is exceeding your current throughput, determine if there is a bottleneck slowing down your operation. If your bottleneck is at the cure cycle, can you add another oven (https://reliantfinishingsystems.com/powder-coating-equipment/powder-coating-ovens/) to improve your capacity? If you're losing time loading and unloading the parts on racks, is it cost effective to add more employees or build more racks? Evaluate your current system and see if you've done all of the simple and affordable expansions to your current operation. Bring in a consultant if you need expert advice. Sometimes a simple fix, like adding another gun or hiring an assistant for your coater, can significantly increase your throughput. If you have already upgraded your batch system and solved all of your bottleneck and speed issues, investing in an automated line is the next logical step to increase production.
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If you need stringent quality control, an automatic line provides repeatable and consistent finish quality that is tough to match with a manual coating operation. Automatic gun systems from companies like Wagner, Nordson and Gema can be programmed to apply specific amounts of powder at just the right setting for best coverage. The process can be repeated automatically for each part. As long as the equipment is properly maintained, the results are ideal and consistent. If your current manual approach is too erratic because your coater is having trouble keeping up, or your customer's finish requirements are very specific, an automatic system can provide highly consistent results when properly operated and maintained by skilled employees.
There are several common finishing specifications that you may be asked to meet in order to capture and retain a client's business. Some of these finish standards require you to employ a specific pretreatment process to achieve acceptable results. Others may simply require finished parts to pass a durability test. Depending on your industry or your end-customer uses, your powder coated parts may need to meet national specifications before they can be used in the field.
One group of standards includes the AAMA (American Architectural Manufacturers Association) , , and aluminum specifications. Here is a link to a chart with a comparison of the three standards:http://www.aamanet.org/upload/file/--_Comparisons_4-6-11.pdf
Each standard requires more extensive pretreatment and powder quality processes than the lower one. For example, the specification can be passed by a manual operation, but the , and definitely the , require an automatic pretreatment process (usually of 4-5 stages or more). Dip tanks can work for specialty parts, but if you are looking at part counts of 1,000-2,000 per day, manual solutions are just not practical. Hanging parts on an automatic line is the most efficient way to prepare large quantities of them consistently. Knowing your production requirements and parts specifications makes your system decision process much simpler.
Cost management is an integral part of efficient production. Reducing labor costs on a per part basis can propel a company forward. Automatic lines can almost always reduce the amount of labor required when compared to their manual counterparts, but there is a minimum of how few employees it takes to run an automatic line.
Typically in a small automatic line you will need someone to load the parts, another person to run the automatic spray booth and perform manual touch-up of problem areas, someone to inspect/unload the parts, and a finish line manager who makes sure the employees are doing a quality job and the equipment is running properly. At least one person needs to know how to adjust the pretreatment section and how to maintain the equipment so that the line remains operational. A minimum of 3-5 employees is recommended for even a small automatic line.
Automated lines are sized based on the largest, densest parts that will be coated. The pretreatment and curing processes are often calibrated to get premium results with specific parts. Shops that routinely deal with parts that are in the same general size and density range are the best suited for automated coating lines. If you have parts that are substantially different in size and density (such as 10' long sections of 3' wide railing, heavy 15' by 15' by 20' machine parts and thin 4' by 4' by 4' pre-assembled frames), an automated curing line may not be practical. Although a single automated system can be set up to accommodate all of these parts, the costs to buy and operate it may be prohibitive.
The other consideration that may make an automated system impractical is if your company does not operate in a fairly consistent way from day to day. Specifically, if jobs are frequently being leap-frogged in line ahead of other work or your operating hours vary widely from day to day. It takes a while to get an automated system up and running, and it takes longer than batch equipment to shut down at the end of the day. Shuffling parts around, changing set-ups and re-starting the line can quickly offset the benefits that make an automatic line effective. Automated powder coating lines get the best results when they are used in a consistent and routine manner.
If you can satisfy your production and cost requirements with a batch system, you are better served with the flexibility and lower cost of a well-made batch system. However, if your production quotas or part specifications require it, an automated line may be the obvious solution. We always recommend that you have a clear understanding of your production goals before making a system purchase.
If you're still debating whether you need an automated powder coating system, here's a summary of the benefits and drawbacks of an automated line, as compared to a batch system.
Automated Finishing System Benefits:
Automated Finishing System Drawbacks:
Careful cost analysis should be performed before deciding on an automatic finishing system. Automatic lines can be very beneficial and improve profitability but their functionality is very specific. They are simply not as versatile as manual batch systems. Pretreatment stages, amount and type of powder to be applied, curing schedules and cool down times must all be calculated before the equipment is manufactured. If you'd like to learn more about the various types of powder coating media, the common steps in chemical pretreatment, and other helpful information that must be taken into account when specifying an automated system, check out our other articles by visiting our Resources page.
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