The demand for coil coating has increased significantly, yet there remains excess capacity in the marketplace, so being a strong global competitor is a challenge. These truths have changed the metal coating industry, with downward price pressure making it more difficult than ever to stay profitable and successful.
While Coil Coaters are focusing on leaner operations to achieve real cost reductions, trying to maintain profitable margins, their customers are demanding higher quality, smaller lot sizes, and more frequent shipments – which would tend to reduce efficiency and drive an increase in cleaning costs. Many coaters adding Saint Clair Systems’ Profile Correction Module (PCM), have found it helping to reduce the cleaning costs in their metal coating operations.
There are many ways that coaters can improve their coating system's efficiency. However, identifying the most time and cost effective option available to them is key. Cleaning costs in the coil coating world consists of four major expenditures:
- Solvent cost
- Labor cost
- Waste paint and disposal cost
- Downtime cost (which, in turn, creates a lost opportunity to produce a saleable product)
The PCM can help combat all of these costs by reducing the system fill volume, enabling improved cleaning while using less solvent, and shortening color change time. By combining the best of two-roll and three-roll coating systems, the PCM system helps to reduce these costs.
1. Reducing Fill Volume
2. Improved Cleaning with Less Solvent
3. Shorter Cleaning Cycles
When balancing the increased downtime associated with short-runs, and the shorter cleaning times that the PCM provides, coaters often see a net increase in the amount of available production time. Although often not recognized as a benefit, this can be worth much more than all of the above combined. More saleable production time means greater revenue potential with no change in overhead.
Reverse the Slide
Coil coaters are operating under greater pressure than ever before, and many of these pressures manifest as cleaning costs. By implementing the PCM into their coil coating process to reduce system fill volumes and minimize cleaning cycle times, many coaters have been able to convert some of their cleaning downtime back into valuable production time.
Download the free Dimension Request Memo to learn how we can customize solutions for your line.