India Powder Coating  
      IPC-E Newsletter: June  2004  
  Welcome to the June 2004 edition of the IPC e-newsletter.

This edition of the newsletter contains:

News features.
The Powder Coating Manual (Part 29)
Exhibitions and Conferences in   June and July 2004

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    News Features      

Off Topic
Transit of Venus

On June 8, 2004, Venus will pass in front of the Sun as seen from the Earth (just like a solar eclipse). Transits of Venus across the disk of the Sun are among the rarest of planetary alignments. No one alive has viewed this rarest of all eclipses: The Transit is when Venus moves directly between the Earth and the Sun. Only six such events have occurred since the invention of the telescope; the most recent in 1882.


For further information click on these links
Link1 Link2, Link3

Advertisement Feature

Mitsuba Systems introduces new Electromechanical Oscillator 


Multiple guns can be mounted on arms extended from the carriage which are capable of performing same or various motions. 

There is a facility to attach fixed guns which can be angled to access difficult coating areas. 

The carriage is programmed to move the vertical mounting bar at variable stroke and speeds. 

The carriage moves up and down through AC geared motor. The carriage is supported by a very sturdy frame structure. The entire waggler is on castor wheels to facilitate easy movement during colour change

Stroke Speed 0 - 28 cycles / minute (Infinitely Selectable)
Angle of Swing Adjustable upto 90 deg. 
Max No.of Guns To Suit Application
Control Variable Frequency
Drive Motor Geared Half HP. AC Motor 
Input Voltage  Single Phase 230 V AC (Other voltages on request) 
Power   0.37 KW (1/2 HP)

To know more about MITSUBA products please visit 
Or contact: 
Mitsuba Systems,
34/H, Laxhmi Industrial Estate,
New Link Road, Andheri (W),
Mumbai - 400 053
Tel : 0091-22-26318633/26334735/56924151/52/53/54
Fax : 0091-22-26316565

Dow Epoxy Price Rise in Europe, Middle East, India and Asia Pacific

Horgen, Switzerland – (6 May 2004) – Effective 1 June 2004, or as contract terms allow, Dow Epoxy Products and Intermediates (EP&I) will be increasing its prices for Epoxy resins.

In Europe, including Western Europe, Eastern Europe and Turkey, Dow is aiming for an increase of 150 Euro/MT for its liquid and solid epoxy resin grades, as well as an increase of 120 Euro/MT for its solid solution epoxy resins and standard brominated resins. The increase for specialty resins varies by product.

In the Middle East and Africa (MEAF), the Indian Subcontinent and Asia Pacific, Dow is aiming for a 200 $/MT increase for its liquid and solid epoxy resin grades, as well as an increase of 150 $/MT for its solid solution and standard brominated resins. The increase for specialty resins varies by product.

Goodlass Nerolac announces record growth

Goodlass Nerolac Paints, one of the leading paint companies in India, declared for the financial year 2004 a turnover of INR 9.25 billion (1 EUR = 54 INR), marking a record growth of 16.97% over FY 03. The net profit of the company increased by a whopping 45.48 % over last year and stood at INR 580 million. Commenting on the announcement, Mr. H. M. Bharuka, Managing Director, Goodlass Nerolac mentioned, "Our topline growth this year, is the highest in the industry, primarily driven by the growth in the Automotive sector and amply complimented by the superior performance of the Architectural segment. Our focus this year has been more on the profit mix and we have been able to absorb the inflation in raw material prices through reduction in overheads and operating efficiencies."

Asian Paints Subsidiary Inks Technical Consultancy Arrangement with Berger Paints Pakistan
Mumbai, May 5, 2004… Berger International Limited (BIL) the Singapore based subsidiary of Asian Paints, Asia’s fourth largest paint company, has entered into a technical consultancy and advice arrangement with Berger Paints Pakistan Limited, the second largest paint company in Pakistan.

This arrangement also puts at disposal of Berger Paints Pakistan Limited through Berger International Limited, the technical expertise and technology of Asian Paints’ group companies.

High-tech exhibition trio succeeds again

Nuremberg, April 2004. 13,341* trade visitors - plus almost 4,000 congress participants - is the positive result of the three-day exhibition trio POWTECH / TechnoPharm / ExploRisk, which ended in the Exhibition Centre Nuremberg on 18 March 2004. This equates to 7 % more visitors over the previous event. The internationality of the trade visitors and congress participants rose to a total of 31 % from over 80 countries. 873* companies (2002: 864) presented their products and services for mechanical processing technologies and process engineering at the three exhibitions.

"Whereas general capital goods exhibitions have considerable acceptance problems, POWTECH has succeeded in clearly consolidating its position as leading exhibition for the whole field of mechanical processing technology", sums up Claus Rättich, Director of Exhibition Management (Own Events) at NürnbergMesse. Exhibitors and visitors confirmed that TechnoPharm as second trade fair in the trio has now finally established itself as Europe's leading forum for decision-makers in the development, manufacture and analysis of pharmaceutical, cosmetic and health food products.

"Trade fairs with a clear profile, proven communication quality and above all a convincing benefit-cost ratio are still accepted to a high degree by the exhibiting and visiting industry, and this trio is one of the events still fully accepted", emphasizes Claus Rättich.

The mood among the exhibitors and visitors was very good - the exhibitors at the combined event especially mentioned the calibre and competence of the trade visitors.

The response from the visitors was also good. In a survey conducted by a neutral institute, more than 96 % of the trade visitors stated they were extremely satisfied with the products offered at the three trade fairs.

J&N loses gloss, referred to BIFR
KOLKATA: Whenever you think of colour, think of us. Perhaps never ever anymore. Once identified with this famous catchline, paint major Jenson & Nicholson (J&N) has lost all colour.

Crippled with severe financial debts, the company has been referred to the Board for Industrial and Financial Reconstruction (BIFR). Manufacture of paints has come to a trickle with most of its factories, including the Panvel unit, having almost shut down and production at Naihati having practically stopped. Financial institutions like IDBI are currently contemplating various options, including transfer of bad debts of J&N to ARCIL, its asset reconstruction company. Institutional sources in the know of developments said the company had earlier indicated prospective buyers to bail it out. But, with no deal forthcoming, the company found itself in troubled waters, following which it approached the BIFR. The latter is yet to give its final decision.

Sources hinted that with polls round the corner and with the government itself thinking of doing away with the BIFR, it may be a long way before something concrete comes up for the paint company.

Most of J&N's creditors, including banks and financial institutions, had declared J&N a non-performing asset (NPA). While lead banker Allahabad Bank has already filed a suit in the court, lead institution IDBI is said to be keeping its options open on the J&N account. While taking responsibility of the assets through the securitisation route is possible, the other option would be to hand over the assets to ARCIL, subject to the approval of 75% of the lenders and the ARC. Although the latest figures could not be ascertained, J&N's total secured and unsecured debts are estimated to be over Rs 160 crore.

Signs of a financial crisis has been showing over the last one year, after it chose to close down its corporate office in Kolkata citing huge business losses. Naihati has seen a massive cut in production levels from a high of 7.55 lakh litres a month four years ago to hardly any production at present.  It's decorative factory at Sikandrabad is said to be operating at much low levels compared to its big capacity of almost 3 lakh litres. It has also pruned number of branches across the country from 52 to 12 in recent months.

Sources in the know of things said that even employees across all levels have problems with their salaries. Most of the employees in the eastern plants have not received salaries for several months as well.

Norway-based Jotun is to invest ?1M in a new powder coatings plant in Indonesia. The 2000-tonne facility, which has been approved by the Indonesian Investment Coordinating Board, will be at Tangerang in Banten Province. Europ Chem News, 19-25 Apr 2004, 80 (2096), 26

Thailand: TOA Paint planning expansion in Vietnam
Coatings Flash - May 03, 2004
TOA Paint (Thailand) is taking another step to expand its business abroad by building a factory in Vietnam, aiming to generate sales of USD 100 million from the fast-growing Vietnamese market within five years. Chairman Prachak Tangkaravakoon said TOA had purchased 30 rai (= 48,000 square meter) of land in Ho Chi Minh City for the factory which may be developed in five phases. The first phase, which requires a minimum investment of 300 million bath (1 EUR = 47 baht), is scheduled to be operational in the first quarter of next year.
The factory in Vietnam would mainly serve the fast-growing Vietnamese construction market and also export some of its output to Laos, he said. It will be the second overseas facility for TOA, which has operated a plant in Shanghai for seven years.

Honda Announces $123M Paint Shop for Marysville Auto Plant
Inside Paint

MARYSVILLE, Ohio, May 11 - Honda of America Mfg. unveiled plans today to construct a $123 million paint facility at its Marysville Auto Plant, continuing Honda's commitment to a cleaner environment, flexible and  efficient manufacturing, and high-quality products for its customers.....<more>

Asian Paints overseas subsidiary, Berger International Limited exit operations in Malta
Inside Paint
Mumbai, May 13, 2004: In an announcement made today at the Singapore stock exchange, Berger International Limited (BIL), the overseas subsidiary of Asian Paints, announced it would divest its stake in its subsidiary Berger  Paints (Malta) Limited (BPM)....<more>

New Akzo Nobel decorative coatings plant in Vietnam

Akzo Nobel is underlining its commitment to investing in Asia with the construction of a new factory for decorative coatings in Vietnam. Work on the facility, which is situated in one of the expanding industrial areas outside Ho Chi Minh City, has already started. Operated by the company's Decorative Coatings International (DCI) business, the new premises - located on a 40,000 square meter greenfield site at the Amata Industrial Park in Dong Nai province - will significantly boost production and lead to a gradual creation of new jobs over the coming years.
Akzo Nobel's DCI business has been producing and selling architectural paints in Vietnam since 1992. The new factory, which is 35 kilometers from the current Ho Chi Minh City plant, is expected to start production by the first quarter of 2005.

DuPont, Gail enter marketing alliance
NEW DELHI, APRIL 8: DuPont and Gas Authority of India Ltd (Gail) have entered into a marketing alliance to jointly develop markets for DDG three-layer polyethylene pipe coating systems (used on steel pipes). Under the alliance, both companies will jointly market the product in India, Arabia, Turkey and Russia.

‘‘DuPont is very pleased to have this alliance with Gail. It allows us to offer solutions that contribute to protecting national assets — India’s pipelines, and to contribute to the country’s economic growth by offering world-class solutions for protecting pipelines throughout the region,’’ said DuPont India president Henrique H Ubrig at the signing of the agreement with Gail in Delhi on Thursday.

Gail chairman and managing director Prashanto Banerjee said: ‘‘Given the technical soundness of the system and the strengths of each company, we are confident the association will be a mutually beneficial one.’’ The DDG system is for the exterior protection of Gail’s new steel pipelines, the DuPont statement said. DuPont and Gail have been working jointly in recent months.

Roanoke metal-finishing shop under investigation by EPA
A metal-finishing shop in downtown Roanoke is under investigation by the U.S. Environmental Protection Agency, officials said Thursday. aul Truntich, the city's environmental administrator, confirmed that Advance Metal Finishing at 523 Norfolk Ave. S.W. is under scrutiny but said he could not disclose exactly why the EPA was conducting the investigation.

Special agents with the EPA's Criminal Investigation Division spent Thursday looking into the sanitary sewer lines through manholes on Norfolk Avenue near its intersection with Fifth Street Southwest. usan Helbert, EPA assistant special agent in charge, said the group was investigating a complaint but would not say who made the complaint or exactly what the EPA was searching for.

"We get involved when we believe it's a serious concern for the environment," Helbert said. But, she said, there was no reason to believe there were any health or safety concerns. Helbert said the EPA was expected to wrap up its search late Thursday. Truntich said the investigation had been going on longer than the one day, but he wouldn't say how long.  U.S. Attorney John Brownlee said the investigation was a pending matter and that he couldn't comment on it.

Metal finishing is the process of changing the surface of an object to improve its appearance or durability. There are many ways to finish metal, including electroplating, organic coating, powder coating, anodizing, electropolishing and phosphate coating. It can be done by spray applications, chemical baths, electrodeposition and other mechanical applications.  Electroplating, a common finishing method, involves applying a thin metal coating by using an electrochemical reaction that pulls metal particles from a sodium solution and binds them to their host. Parts can be plated with zinc, nickel, brass, copper, silver or black oxide.

A Virginia Waste Minimization Program fact sheet on waste reduction for metal finishers posted on the EPA's Web site says typical wastes generated are industrial wastewater and treatment residues, spent plating baths and process baths, spent cleaners, and waste solvents and oils.

Experts say powder may have been trigger

SPECULATION was mounting last night that a gas oven was the source of the explosion that destroyed the building. Shortly after the blast, the gas-supply company Transco said the supply to the building had been switched off, but that it had not been a factor in the explosion. Workers who were inside at the time said they believed the blast originated from part of the factory where metal was coated with plastic powder. Experts in explosions said the powder could have turned a relatively small explosion caused by a gas fault into the devastating blast that destroyed the factory. Professor Barry Moss, an expert in thermo-fluids and combustion at Cranfield University, said any explosion was "driven" by the presence of some kind of flammable gas. This could come from gas in pipes, or a faulty gas appliance, vapour from a solvent, or chemical or a fine powder.

He said there may have been an initial explosion which threw plastic powder used in the coating process into the air.That may have ignited, causing a major explosion. This would have increased the pressure inside the building, pushing out supporting walls and causing the whole structure to collapse "It could be a situation where perhaps the initiating event was the oven, and that perhaps in some way dispersed the powdered plastic so you got a much larger volume of flammable material," Prof Moss said. "As a result of plastic being dispersed into the air, it could have led to a much greater explosion, depending on the amount of material dumped into the air.

"Even though the particles [of powdered plastic] are small, they are dense in comparison with a gas, and therefore the mass involved might have been sizeable. This is an event that produces an over-pressure. How the over-pressure interacts with a structure depends a little bit on the detail of the structure. "You don’t need a huge over-pressure to knock walls down," Prof Moss explained. "If you knock out a few walls and the building collapses, that’s not the same as blowing the whole building up. "It’s like the World Trade Centre. You destroy a small part and the rest falls through it. That perhaps could give you what looks to be a disproportionate amount of damage [compared with the explosion]." Colin Hindle, the president of the Scottish Plastics and Rubber Association and a lecturer in polymer technology at Napier University in Edinburgh, said Stockline was basically a warehouse for storing sheets of plastic, while ICL did the manufacturing. He said plastics factories were not particularly prone to such explosions."While, if there was a fire, some of these plastics would be a fuel, it would never explode. They are not that easily ignited, and certainly they are not likely to explode, except possibly if there was a very fine powder," he said. "There was an explosion but no fire. That surprises me. An explosion like that would almost certainly be followed by a fire."Temperatures of 200C or 300C at most, he said, would be used to mould the plastic."There’s not much chance even of a fire, let alone an explosion," said Mr Hindle.

"A chemical explosion seems to me to be less likely. The most flammable thing they would stock would be an adhesive, which would be in a sealed container anyway." But he agreed with Prof Moss that the powdered plastic may have had a role in causing the blast, although he said that using it as part of the coating process was routine in the plastics industry. "Coating plastic on to metal is a common occurrence, whereby you heat the metal up normally until it’s pretty hot and then dip it into a powder coating," Mr Hindle said."The powders are potentially a source of explosion because you get static, but the vessels they are in have to be earthed according to the legislation."

Battling the rising offshore tide l
Valley's Perma-Finish Inc. recovering from battering and is winning business back
If losing business to companies that have gone offshore sounds like something that happens to the other guys, let Perma-Finish be a lesson. The company's founders thought that once, too.

In late 2003, Perma-Finish Inc. lost one of its biggest customers, Tempe-based Rockford-Fosgate, an audio component manufacturer that sent its work overseas. "When you hear about all this business going to China, that was us," said Richard Quiroz, vice president of Perma-Finish, which specializes in a painting process called powder coating for audio equipment, building materials and lighting fixtures.

Perma-Finish took the hit just as Quiroz and President Angel Castellano were seeing the highest sales in Perma-Finish's 19 years and recouping from devastating losses in 1997. he pair have been working aggressively to restore business while striving to become the dominant powder-coat paint applicators for the building industry in the United States. They heard in the news that the manufacturing sector is starting to turn around. Some accounts that went offshore, or ones that tried to paint their own products to cut costs, have been are returning to Perma-Finish. It's too soon to tell how this will affect business, Quiroz said. "We're by no means out of the woods," Quiroz said. "We're almost in a crisis mode where we see the big guys outsource to Asia."

Their profit margin has increased 6 percent since their leanest period in 1997. That year, co-founder and friend Jerry Greitzer died. Without their business-savvy partner, the company faced financial ruin, Quiroz recalled. Sales bubbled at $2.4 million, but the company was socked with $3 million in losses. Sales dipped, creditors were calling, and utility bills piled high. The pair sought help at the Maricopa County Community College Small Business Development Center and the Arizona Public Service Academy for the Advancement of Small, Minority and Women-owned Enterprises. Perma-Finish enjoyed top sales and profit margins from 2000 to 2002. By the end of 2002, sales were peaking at $4 million, with 12 percent profit.

"We needed to dig ourselves out of the hole, and we did," Quiroz said.

More importantly, they became competent businessmen. Castellano wrote a production program that has helped the company become more efficient. Quiroz, Castellano and the late Greitzer got their start in aluminum anodizing. In the energy crunch of the early 1980s, their customers switched to liquid paint, a cheaper alternative. That caused them to diversify. "We came across powder and saw that it was the coating of the future," Castellano said. Greitzer had the idea to switch from anodizing to powder-coat paint finishing.  "It was absolutely like jumping in at the deep end," when Perma-Finish started with 10 employees in 1985, Quiroz said. "It was sink or swim. We chose to swim."

The company now has about 70 employees and has ventured into retail. A few years ago, Castellano and Quiroz developed Link-It, a modular system of decorative fences, trellises and arbors. The entire manufacturing process is done in-house. One of the products, a corner fence kit, was featured on QVC. It wasn't a big seller - callers bought up just 200 of 1,400 kits - but the TV exposure helped to launch Perma-Finish's first foray into retail. Link-It products have become a hit in the home garden industry. Frank's, the largest nursery in the United States, ordered $50,000 worth of modular fences and some local nurseries carry Link-It products.

Castellano and Quiroz now hope to snag a deal with big-box retailers such as Lowe's or Home Depot.

Trio Industries Group, Inc. Partners with DuPont and the University of Southern Mississippi
DALLAS--(BUSINESS WIRE)--May 26, 2004--Trio Industries Group, Inc. (Pink Sheets:TRIG), announced today that it is negotiating a Joint Development Agreement with the Polymer Science Institute at The University of Southern Mississippi, the leading polymer science research foundation in the United States. Trio Industries, a developer of technology and applications in the wood products field, will develop technology with The University of Southern Mississippi utilizing polymers and high performance materials applications on composite wood panels. In an effort to enhance this collaboration, Trio Industries has engaged in preliminary discussions with DuPont Performance Coatings to participate in the development of advanced powder-coating products for composite wood panels. DuPont Performance Coatings has developed a new powder-coating process with low curing temperatures that Trio Industries anticipates utilizing as its powder coating of choice for composite wood panels.

Trio Industries Group, Inc. is seeking to become the first vertically integrated manufacturer of powder-coating on wood in North America. Trio intends to control the supply chain from the forest to finished powder-coated products providing the Company strategic advantages as major kitchen cabinet, bathroom vanity, and office furniture manufacturers embrace the outsourcing platform of the future.

Trio Industries Group, Inc. Enters Into Development Contract With Nordson Corporation and Delle Vedove USA, Inc. / Superfici USA, LLC
Thursday May 20, 10:18 am ET
DALLAS, May 20 /PRNewswire-FirstCall/ -- Trio Industries Group, Inc (OTC Pink Sheets: TRIG - News), announced that it is entering into a development contract with Nordson Corporation (Nasdaq: NDSN - News), the world's leading producer of precision dispensing systems and manufacturer of technology-based systems for curing and surface-treatment processes. Nordson, a company with year-end 2003 revenues of approximately $660 million, will develop for Trio a proprietary flat line finishing system for powder-coating on wood products.

This development effort includes participation by Delle Vedove USA, Inc. / Superfici USA, LLC, a world leader in designing finishing systems for wood products. They will collaborate with Nordson Corporation in developing for Trio the proprietary flat line finishing system for powder-coating on wood products. The projected timing for completion of this line will be in the fourth quarter of 2004.

Trio Industries Group, Inc. is seeking to become the first vertically integrated powder-coating on wood manufacturer in North America. Trio intends to control the supply chain from the forest to finished powder-coated products providing the Company strategic advantages as major kitchen cabinet, bathroom vanity, and office furniture manufacturers embrace the outsourcing platform of the future.

Sun Announces First Japanese Sun Java(TM) Enterprise System Customer Nippon Paint
Wednesday May 19, 12:00 pm ET
Nippon Paint Plans to Migrate Mainframe Architecture To Open Standards-Based Sun Architecture; Expects To Reduce Total Cost Of Ownership By 50 Percent

SANTA CLARA, Calif., May 19 /PRNewswire-FirstCall/ -- Sun Microsystems, Inc., the creator and leading advocate of Java(TM) technology, today announced that Osaka, Japan-based Nippon Paint Co., Ltd. has purchased and plans to deploy the Sun Java(TM) Enterprise System, an integrated, open standards-based software system as its corporate-wide IT infrastructure software standard. The Java Enterprise System software was purchased through Sun iForce(TM) Partners CSK CORPORATION (CSK) and ITOCHU TECHNO-SCIENCE Corporation (CTC), demonstrating continued partner momentum in the Asia Pacific region. Nippon Paint selected the Java Enterprise System running the secure, reliable, scalable and highly available Solaris(TM) 9 Operating System based on Sun's innovative pricing model and open architecture. The company plans to migrate its distribution, logistics, human resources and finance applications, currently hosted by legacy mainframes, to the Java Enterprise System platform by 2006.

By adopting the Java Enterprise System, Nippon Paint expects to reduce operational costs associated with system management and upgrades, and increase time-to-market of new applications and technologies. Nippon Paint will also benefit from an open standards-based architecture, ensuring interoperability and more proactive and productive management. Additionally, through this migration, Nippon Paint projects the transition will cut its total cost of ownership (TCO) by 50 percent.

Nippon Paint plans to utilize the following Java Enterprise System components including the Java(TM) System Directory Server, Java(TM) System Identity Server, Java(TM) System Portal Server, Java(TM) System Messaging Server and Java(TM) System Web Server. Additionally, Nippon Paint plans to leverage Sun's robust hardware platforms such as the Sun Fire(TM) B100s blade servers for front-end applications, the Sun Fire(TM) V480/V440/V240 servers for application processing, and the Sun Fire(TM) V1280 and V880 servers for database operations.

SK Finishing has lofty goals for its new home in Lorain

LORAIN -- A company that has recently moved its operations into Lorain wants to color coat the industrial world in northern Ohio and is setting lofty goals to serve that need at a faster and better rate.

After securing a loan from the Lorain Community Development Department to move its equipment and promising to keep the business in the city, SK Finishing Inc., a 26-year-old color coating company now owned by Roger Mahoney, 42, of Grafton, purchased the struggling Class A Coatings Inc. in Lorain in February.

In March, SK moved all of its color and powder coating operations to Class A's Lorain facility from North Abbe Road in Elyria.

SK Finishing now is on a 3.7-acre property at 2201 W. Park Drive on Lorain's west side.

Not only did the industrial color coating company quadruple its space to 25,000 square feet when it moved, it added jobs and hopes to add about 30 more in the fall, both in production and sales, Mahoney said.

''We want to develop a world-class sales team and expand our sales radius to cover all of northern and northeast Ohio,'' Mahoney said.

Pending further financing, SK hopes to add a third line and expand its facility by 12,000 square feet without seeking any tax abatements, Mahoney said.

The company currently has 100 clients, and color coats parts for manufacturers of wheelchairs, telecommunications equipment, automotive components and purchase displays.

American Greetings in Cleveland, Westlake-based Nordson Corp. and Sunrise Medical Inc., a wheelchair manufacturer based in Carlsbad, Calif., that has a facility in Avon Lake and produces 50,000 wheelchairs a year, are among SK's clients.

SK now employs 40 people and has an annual payroll of $750,000, generating $20,000 a year in annual property taxes, Mahoney said. When it adds the estimated 30 production jobs that will pay $7 to $9 an hour in the fall, that will add another $500,000 a year in payroll, Mahoney said.

He said when the company expands its sales team and the radius it covers, it projects to double its revenue of $2.5 million it made its 2003 revenue of $2.5 and triple its revenue within five years.

SK currently is launching a national campaign, ''Quality Powder Coating Done Right ... Now,'' and ultimately would like to become a company with an annual $15 million revenue, Mahoney said.

SK's motto is becoming ''service, production and quality.''

''We're basically acting as an extension for other companies that manufacture parts who need to have them color coated at the end of the manufacturing cycle. We hope quality and quickness will mean something for manufacturers who need parts color coated. The city's community development department was helpful in accommodating our move here,'' according to Mahoney.

He said that manufacturers sometimes have waited at their facility for the work to be done.

''We're the heroes when manufacturers come in and don't have to wait a week to have their parts painted,'' Mahoney said. ''Some companies have even come in and waited while their parts were done, and carry them right out in the box. By being able to do that, companies are beginning to realize they no longer have to wait for their parts or have to get them from overseas.''

On the average, SK has the ability and personnel to turn out color-coated parts in 24 hours and the company works with about 20 colors a day, Mahoney said.

SK also has the capability to do custom colors within five days, using the example of being able to implement the ''Moen Blue'' color on parts for the plumbing fixtures company.

Mahoney said that SK is one of two color coating companies in the United States that has the capability to accommodate the Westlake-based Nordson Corp. that makes powder coating equipment.

''We believe that when you do the color coating work for a powder coating business that says a lot,'' Mahoney said. ''A lot of the companies that used to do their own color coating in-house are seeing that it's more cost efficient to have someone else do it.

''There will always be a need for products that are built here,'' Mahoney added. ''They know they can't wait a week for the parts to come from China. That's why we say we can do color coating right now.''

SK currently has two lines, a high-speed automated line and a ''batch system'' line for larger parts. Mahoney and his general manager, Jim Gallagher, hope to add a third line.

The third line would be another high-speed automated line to accommodate large parts. SK currently can color coat products as large as a medium size car, Mahoney said.

SK has adopted a strategy called lean manufacturing, which is geared toward achieving the shortest production turnaround time by eliminating waste and mistakes. SK currently has three shifts working daily.

Currently, for every 1 million parts SK color coats, there are just 550 mistakes, Mahoney said.

Gallagher said that being able to turn out the work at a faster rate has been helping the company make a name for itself.

''What we're hoping to do here is to at least force the other powder-coating companies to step up to the plate, and hopefully they won't be able to,'' said Gallagher. ''We want to take the business to the next level simply by being the best. We want to create a good company and a good place to work.''

''If we can add a third line, we'll be able to really open the business up,'' said Gallagher, who has been with the company for 18 years. ''We'd be able to do five times as many parts as we do now. Each month we've been in our new facility, we've been setting records.''

Mahoney said he first became interested in electronics when he began experimenting with them when he was in the fifth grade.

Soon after graduating Lorain County JVS in 1980 in industrial electronics, he acquired a job with Accurate Electronics in Elyria. He purchased the business in 1991 and became partners with Patrick O'Connel, who now is deceased.

O'Connel was the one who first became involved in powder and color coating when he owned and operated Strip and Klean Furniture Service in Elyria.

Mahoney sold off Accurate Electronics in 1996 and became more involved with the powder coating business, which only had two clients.

O'Connel died in 1996, and Mahoney bought out the powder and color coating business in 1997.

''I had a rough 1996. In 1997, we started turning things around,'' Mahoney said. ''In 2000, our sales grew by 25 percent, and we haven't had a backward year since.''


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    Exhibitions, Seminars, Course, Lectures  
CEPE - Annual Conference and General Assembly
June 3 - 4, 2004 General Assembly; Barcelona/Spain
More Information from:CEPE, Av. E. Nieuwenhuyse 4-Bte 10, 1160 Brussels, Belgium, Fax: +32 (2) 676-7490, 

Asia Pacific Coatings Show 2004
June 3 - 4, 2004,Exhibition, Conference; Bangkok/Thailand
More Information from, dmg world media (uk) ltd.,Queensway House, 2 Queensway , Redhill,RH1 1QS Surrey,Great Britain , Fax: +44 (1737) 85 50 34,, 

Coatings Science Short Course
June 6 - 11, 2004,Short Course; Fargo, North Dakota/USA
More Information from,North Dakota State University, Carol Johnson ,
PO Box 5376, Fargo, ND 58105,USA, Fax: +1 701 231-8439 , 

European Coatings Conference:
Smart Coatings III
June 7 - 8, 2004 Congress; Berlin/Germany
More Information from Vincentz Network, P. O. Box 6247, 30062 Hannover, Germany, Fax: +49 511 99 10 279,

7th International Coatings for Plastics Symposium
June 7 - 9, 2004,Symposium; Troy
More Information from Paint & Coatings Industry Magazine,2401 W. Big Beaver Road,Suite 700,Troy, MI 48084,USA, Fax: ++1 248 362-0317, attn: Keri Wrobel,, 

Coatings Science for Coatings Chemists

June 7 - 10, 2004 Seminar; Hattiesburg/USA
More Information from The University of Southern Mississippi, Polymer Science Research Center, Deborah Witherby
P. O. Box 10076. 39406-0076 Hattiesburg, MS, USA , Fax: +1 601 266-5504
, , 

2004 International Marine and Offshore Coatings Conference & Expo
June 7 - 9, 2004, Conference; Virginia Beach, VA/USA
More Information from, National Paint & Coatings Association, Dorothy Brawner , 1500 Rhode Island Ave., NW
Washington, DC 20005-5597,USA, , 

Formulating Principles for Coatings

June 7 - 10, 2004, Course; Hattiesburg/USA
More Information from, The University of Southern Mississippi, Polymer Science Research Center
Box 10076, 39406-0076 Hattiesburg, MS ,
USA, Fax: +1 601 266-5504, 

Advances in Emulsion Polymerization and Latex Technology
June 7 - 11, 2004 Seminar; Bethlehem/USA
More Information from,Emulsion Polymers Institute, Lehigh University
111 Research Drive,18015 Bethlehem, PA,USA, Fax: +1 610 758-58 80,

Business Information for the Coatings Industry

June 10, 2004 Training Course; Teddington/Great Britain
More Information from,Paint Research Association , 8 Waldegrave Road,Teddington,Middlesex TW11 8LD,Great Britain
Fax: +44 20 8943

4th International Symposium on Contact Angle, Wettability and Adhesion,
June 14 - 16, 2004 Symposium; Philadelphia/USA
More Information from,Materials Science and Technology Conferences , Dr. Robert H. Lacombe
3 Hammer Drive,Hopewell J 12533-6124,USA, Fax: +1 212

Paint Defect Analysis Workshop
June 15 - 17, 2004 Workshop; London, Ontario/Canada
More Information from, Paint Performance Consulting , 35585 Pound Road,Richmond,48062 Michigan,USA, Fax: +1 586 727-27 24,
8th Radcure Coating and Inks: Economy & Performance
June 21 - 22, 2004 Conference; Manchester/Great Britain
More Information from, Paint Research Association
8 Waldegrave Road,Teddington,TW11 8LD Middlesex ,Great Britain, Fax: +44 20 89 43 47 05,

Surfex 2004
June 23 - 24, 2004 Exhibition; Manchester/Great Britain
More Information from, Surfex Ltd., OCCA,Priory House,967 Harrow Road,HA0 2SF Wembley,Great Britain, Fax: +44 (20) 89 08-12

1*1 der Nanotechnologie
June 24 - 25, 2004 Seminar; Stuttgart/Germany
More Information from,MSTI,P.O. Box 1050,65836 Sulzbach/Ts,Germany, Fax: +49 6196 585-485, 

Coating Process Fundamentals Short Course
June 28 - 30, 2004,Short Course; Minneapolis, MN/USA
More Information from: University of Minnesota, Dep. of Chem. Engineering & Materials Science
151 Amundsen Hall,421 Washington Avenue S.E.,Minneapolis, MN 55455-0132,USA, Fax: +1 612 626-7246, 

June 29 - July 1, 2004,Exhibition, Conference; Chicago/USA
More Information from,AESF SUR/FIN 2004,12644 Research Parkway,Orlando,32826-3298 Florida ,USA, Fax: +1 407 281-64 46, 

4th International Strategy Conference on Car Body Painting

July 1 - 2, 2004
Congress; Berlin
More Information from:Vincentz Network, Schiffgraben 43, 30175 Hannover, Germany, Fax: +49 511 9910-279,

5. ICCG - International Conference on Coatings on Glass
July 4 - 8, 2004 Conference; Saarbrücken/Germany
More Information from:Leibniz-Institut für Neue Materialien - INM, Dep. of Coating Technology , Im Stadtwald, Geb. 43
66123 Saarbrücken, Gemany, Fax: +49 681 9300-249, , 

  Powder Coater’s Manual ------- Determining the Application Package (Part - 29)  
Selection of the Application Package

There are several factors that must be considered in determining the proper application package.

 The size and shape of the part
 The variety of parts to be run
 The variety of powder chemistry and colors to be run
 Desired film thickness
 Production output
 Design line speed
 Size of the product opening
 Available capital

The part size and configuration will determine the product opening into the booth. The maximum part size is also needed in the selection of the number of automatic guns and their placement, the selection of gun movers and gun attachments, or the determination of the number of manual operators in a particular system. The correct number of guns for a particular application depends largely on the vertical surface to be coated but the shape of the part and the line speed are also factors. Basically, the number of guns should con-sider how much surface will be coated in a given time period and
select enough guns to coat it without above average output per gun. A “rule of thumb” formula for determining the number of guns required considers:

 Design Line Speed
 Coating Thickness Required

 Part Size
roduct height x line speed x mil thickness x the number of sides needing guns, divided by difficulty factor, rounded up to an even number. Difficulty Factor: 240 extreme 300 medium 360 simple

(60" x 10 FPM x 1.5 mils x 2)/300 = 6 guns

One pound of powder covers 192.3 sq. ft. at 1 mil thickness at 1.0 specific gravity and 100 % utilization. Factoring the variables of actual thickness, specific gravity of a particular powder and the actual transfer efficiency
will provide an idea of the coverage that can be expected from a pound of powder.

Testing has shown that low outputs provide higher transfer efficiency. The powder charges better and is less likely to blow by the part or rebound off the surface. So in the selection of guns it is important to avoid using too few guns with high output per gun. Efficiency is improved with the correct number of guns that will allow the system to operate below 30
pounds of output per hour, per gun.

Proper performance in powder coating depends upon the powder particles having an electrostatic charge and the substrate being properly grounded. The charge on the powder particles will determine how well the powder adheres to the part and the rate of film build. As a charged layer of powder accumulates on the surface it develops a force which resists further deposition.

The rate of film build is also related to delivery pressure, gun to target distance, particle size, the time of exposure in the spray zone, gun voltage and the volume of the powder delivered.
 Generally, higher voltage will produce heavier films
 Gun to target distance should be 6" to 12". Generally, a closer position will produce a heavier film and possible back ionization
 If delivery pressure is too high it will blow powder past the part, if it is too low the powder will not get to the part, it will be pulled into the reclaim system.
 A coarser grind of powder will produce a thicker film
 The rate of film build diminishes with longer exposure, however there is still an increase of film with prolonged exposure
 Typically, a larger volume of powder delivered will result in quicker film build

This does not necessarily mean that there is greater transfer efficiency. If a larger volume is delivered the percentage of efficiency may remain the same or decline, applying more powder but also over-spraying more powder. In addition, since a larger volume of powder sprayed will mean more cumulative charge on the part surface in less time there is a greater risk of back ionization when larger volumes of powder are sprayed.

   To be continued....  

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My name is Muoi from a company called Argon Masking Corp. We are a manufacturer of masking supplies for powder coating
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Dear Vivek,
Please advise if you could recommend a source for the supply and installation of a semi automatic Powder Coating Plant.
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On 5th May 05, I got Married
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