As powder-coating applications take the finishing industry by storm, clients are coming to Richards-Wilcox Conveyor for help designing, integrating and reconfiguring their own finishing lines.
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These clients have a lot of questions about powder coating. But there’s one we’ve been hearing more than any other:
“When designing a powder-coating line, should I invest in a manual batch-type system or an automated line?”
The answer isn’t as clear-cut as you might think. In fact, it all depends on your workflow, your volume, your budget, and your floorspace.
Let’s take a closer look.
Manual Batch-Type Systems vs. Automated Lines
For those who don’t know, a manual batch-type system is the more hands-on variety of powder-coating production line. In batch systems, operators begin by manually preparing parts, moving items from one device to another using carts or a manually operated conveyor. Once a batch of parts is ready, it is then coated and cured.
As the name suggests, an automated line automates this process. Rather than using human labor to prepare batches of parts, an automated conveyor system continuously moves individual parts through the entire process, from prep and drying to application, curing and cooling.
So, which is better: manual batch or automated?
The truth is that neither system is inherently better—both have their benefits and drawbacks. One is more efficient, while the other is more flexible. One is more expensive, while the other is more labor-intensive.
How do you find the right system for you? Start by considering these four factors.
#1: Volume & Regularity
In general, automated lines are best suited to coating higher volumes of parts, as long as those parts have consistent sizes and shapes. If you’re coating thousands of similarly sized parts per shift, automated is probably the right fit.
Batch systems are typically slower than their automated counterparts, but they’re also more versatile. While automated systems must be reconfigured to account for irregularly shaped parts, manual systems don’t. It may be more efficient to go manual if you’re working with lower volumes of irregular parts.
#2: Floorspace
Manual systems typically require fewer components – for example, one oven can be used to both dry and cure parts – which makes them a good fit for businesses with limited floorspace.
However, just because you’re tight on space doesn’t mean an automated line is impossible. Richards-Wilcox Conveyor has worked with clients to make automated lines fit in surprisingly limited spaces.
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#3: Speed
Manual batch systems are generally slower than automated. If your powder-coating system outpaces the manufacturing process, then that may not be an issue. But if your powder coating process is delaying output, then you may need to speed things up with automation.
Automated lines can be designed for rapid throughput, creating a constant flow of parts to keep pace with other manufacturing processes. If you need speed, go automated.
#4: Budget
Manual batch-types systems are typically seen as the budget-friendly alternative to automated lines. The upfront cost of manual systems is significantly less; and although they require more human labor, their maintenance costs and operating costs are often much lower.
Then again, the relative efficiency of a system all depends on the other three factors we listed here. If your system is operating at full capacity, producing thousands of products per shift and keeping pace with your other manufacturing processes, an automated line may be necessary to help you meet production goals.
We’ll help you identify and design the optimal system for your finishing line.
Whether it’s a smaller manual operation or a large-scale automated line, Richards-Wilcox can create a system that maximizes your efficiency and helps your business achieve its goals.
From designing layouts and installing conveyors to integrating robotics and automation, we leverage decades of experience and key partnerships to create the right solution for your needs.
Q: I am thinking of changing to a powder coating system and understand that one of the most important decisions is choosing the right powder booth for my application. What are the most important factors to consider when selecting a powder booth?
A: When choosing a powder booth, there are many things to consider. It is also essential to look to the future, meaning that your requirements today may not be the same in the future. Look for something flexible that can grow with your production requirements. Below is a summary of the items to consider:
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- Identify the part's dimension. The part's dimension is important because it will affect the booth size, the number of applicators, and processor speed.
- Next, consider the number of parts needed, which will set the conveyor speed. Understanding the production requirements will help determine the conveyor speed and number of units produced.
- A critical aspect is color-change time. This is important as this helps determine what type of recovery equipment is needed. Typically, color-change powder booths can get a complete color change in 6-10 minutes by following the procedure set up by the manufacturer and by automating much of the color-change process.
Types of color-change booths:
Most color-change booths are designed for manual and automatic applications, but there are differences. If an application requires more manual reinforcement, the booth has a larger manual reinforcement-based operator station. If more automation is needed and minimal reinforcement, the operator station would be smaller. The third booth type is used when more automation is needed, such as a simple gun mover or fixed gun stand on each side. Often, a budgetary proposal up front is the best way to confirm the correct booth and application equipment needed. Typically, a lab test would be conducted.
There is also a different type of powder booth for powder coating vertical extrusions up to 30' tall. This style is unique because it only uses automatic guns without manual reinforcement. For this type of booth, the simpler the extrusion profile, the faster the line can travel, and the more difficult the profile, the slower the line speed.
Similarly, the shorter the part, the faster the line can move as the reciprocator does not have to use up a longer stroke for more travel time.
As a standard, all color-change booths utilize a powder kitchen for the feed center connected to each booth or can be separated if floor space is restricted and feed from boxes, drums, or totes. The control center uses a PLC and can integrate with the customer's plant to track production, stops, part counts, etc. Troubleshooting is done via an ethernet connection back to the manufacturer to save downtime and reduce costly visits.
Recovery Equipment
Color-changing booths are designed to be very efficient in powder utilization, with some designs returning up to 97% of overspray powder back to the system. When you consider that the customer is buying powder daily for production but only invests capital dollars once every 10-15 years for the equipment, it makes sense to add additional items that will keep the daily costs down, so there is a good ROI.
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