THE BUSINESS OF VISCOSITY BLOG



Taking on More Architectural Coatings? Save Production Time

Posted by Mike Bonner

Aug 26, 2015 11:00:00 AM


In our recent blog, "Why Quality Checks are Rising in Architectural Coil Coating," we noted that modern architecture involves:

  • More colors than ever before
  • Short runs
  • High quality demands
  • Long warranty periods
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Topics: Coating Technology, PCM

Use Fluid Process Control to Gain 2+ Hours of Daily Run Time

Posted by Mike Bonner

Aug 24, 2015 11:00:00 AM


We talk a lot about the new reality for coil coaters. Their customers are demanding smaller lot sizes and more frequent shipments. Often they are asking for delivery of just a portion of a coil!

This has driven coil coating runtimes down proportionately. The average coating system run is now less than one hour. In turn, this translates into 1–2 color changes per hour. And if you do the math on that, it extends out to more than 30 color changes per day!

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Topics: PCM, fluid process control

Reduce Cleaning Costs By 20% in Coil Coating Systems

Posted by Mike Bonner

Aug 21, 2015 11:00:00 AM

In our recent blog, “3 Ways PCM Reduces Costs in Aluminum and Steel Coil Coating," we outlined the case of one of our clients who utilized the PCM to address cleaning issues in their coating systems. They reduced their paint delivery system volume by more than 70% which:

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Topics: coil coating, Coating Technology, PCM

Reduce Cost of Paint and Coating Disposal by 10% or More

Posted by Mike Bonner

Aug 19, 2015 11:00:00 AM


Disposal of drums of waste paint and coating is a necessary evil for anyone in the industrial coating or finishing business, but is especially true for coil coaters.

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Topics: sustainability, PCM

Reduce Color Change Costs up to 50% in Coil Coating Systems

Posted by Mike Bonner

Aug 17, 2015 11:00:00 AM


Color changes represent a significant cost to every coil coater – a cost that gets added to every job they run – and as such, a cost that gets passed along to the customer. The components of a color change are the same for every coater. Every color change consumes:

  • Paint
  • Solvent
  • Line time
  • Labor
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Topics: paint and coating, PCM

4 Ways to Use PCM to Increase Metal Coating System Runtime

Posted by Mike Bonner

Aug 14, 2015 11:00:00 AM


In our recent blog, “Increase Run Time: Add the PCM to Coil Coating Fluid Process," we showed that if we remove preventative maintenance (scheduled downtime) from total downtime in industrial coating and other paint and coating processes, we could divide the remaining sources of unscheduled downtime on a coil coating line into five categories:

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Topics: PCM

PCM Coating Technology Cuts Industrial Finishing Setup Time

Posted by Mike Bonner

Aug 12, 2015 11:00:00 AM


Every manufacturing business that survived the infamous “downturn” has increased their focus on operating costs in order to remain viable and competitive. In many markets, however, “remaining competitive” means extending warranties and reducing price. This translates into reducing inventory and controlling what is paid for goods with no compromise in the quality of the goods received.

Coated coil users and those in industrial coating industries are no exception.

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Topics: Industrial finishing, Coating Technology, PCM

3 Ways PCM Reduces Costs in Aluminum and Steel Coil Coating

Posted by Mike Bonner

Aug 10, 2015 11:00:00 AM


One of our coil coating customers in the Southeastern United States specializing in high quality aluminum coating and steel coil coating, found himself at a competitive disadvantage because his line is not equipped with a second top-finish head to provide “quick-change” capability.

Though not alone, this left him with no way to embed cleaning time into his coating system run time, which meant that every minute spent cleaning represented time that the line was down. This was limiting the capacity.

The Profile Correction Module (PCM) provided a low-cost solution to their problem.

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Topics: coil coating, coating aluminum, PCM

Using the PCM to Reduce Partial Drums in Metal Roof Coating

Posted by Mike Bonner

Aug 7, 2015 11:00:00 AM

Partial drums are a big pain for metal roofing coaters, just as they are for all coil coaters. They have to be handled. They have to be stored. They are full of expensive paint, which represents a cost and has to be accounted for on the books of the business – either as an expense or as an asset. Neither of which is an attractive option!

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Topics: paint and coating, PCM, fill volume

The 7 Traits of Highly Successful Coil Coating Systems

Posted by Mike Bonner

Aug 5, 2015 11:00:00 AM


Please excuse the trite reference to Stephen Covey! But in this case, there really are seven traits that we see that signify that we are working with a world-class coater. Truly world class coil coaters are identified by their ability to:

1. Provide a high quality surface finish batch-after-batch
2. Deliver on time, every time

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Topics: coil coating, sustainability, Coating Technology, PCM