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"...stable paint viscosity produced dramatic reductions in viscosity-related defects such as orange peel, gloss and sag, and temperature-related defects such as dry spray."
- Roush, First-tier auto supplier
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Case Study #4
The Opportunity
Alsco Metals Corporation, a leading manufacturer of aluminum residential building products, was experiencing significant quality-control problems with their continuous coating process. Film-build-related issues such as poor color-match and edge-to-edge dry film thickness (DFT) variations, and viscosity-related issues like inconsistent striation patterns (simulated wood-grain finish) were prevalent. Seasonal observations convinced them that the problems were temperature-based. A thorough investigation of potential solutions in use in their industry showed little potential for solving their predicament, so they turned to SCS to devise a way to bring their application temperature under control.
The Solution
SCS developed a method for measuring and recording the actual temperature of the coating material being applied across the entire width of the strip throughout the duration of the production coating run. Using this data, SCS was able to analyze variations in the temperature profile and demonstrate how these variations were directly related to the defects being experienced. Furthermore, it was shown how the system flow dynamic was contributing to these variations and also how minor changes in the configuration of the delivery system could reduce these variations to within acceptable process-control limits. SCS then built and installed a multi-station system capable of controlling the temperature of paint being delivered to each coating head separately and in real time, independent of process influences and changes in ambient temperature.
The Results
By implementing changes to the paint delivery system developed with the recommendations made by SCS, Alsco was able to reduce variations in the thermal profile across the width of the strip by more than 80%, which, in turn, created comparable reductions in edge-to-edge variations in DFT. When these improvements were combined with the ability to select and maintain desired application temperatures, the results were consistent film build and significant reductions in process-related color-match issues across all paint colors and formulations. This led to a 10% reduction in paint usage, and solvent savings on the order of 25 tons in the first year. Furthermore, when these upgrades were incorporated into the PVC application process, they produced stability and control over striation patterns independent of changes in ambient temperature-a feat not previously possible.
(Note - Though this represented the first coil-coating system supplied by SCS, the tools we developed for analyzing and controlling this process have now become the industry standard. For more about this application see "Using Temperature to Stabilize Coil Coating Processes", a two-part article that spanned across the November/December 2005 and January/February 2006 issues of Coil World Magazine)
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