GEMS: The equipment and solution for Wood Polyester Coating

© 2015 Finishing Brands - A Carlisle Company All rights reserved. 04/15 © 2015 Finishing Brands - A Carlisle Company All rights reserved. 04/15

GEMS

Beyond Accurate Mixing

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© 2015 Finishing Brands - A Carlisle Company All rights reserved. 04/15

Introduction

GEMS is the easy to operate 2K mixing solution that audits your paint resin and solvent usage while helping to reduce your solvent waste for up to 5 colours and 2 spray guns.

GEMS’ data capture capabilities provide insights into your daily spraying process and audit your paint resin and solvent usage. GEMS is capable of storing data for distinct production jobs, recording spraying times, colour change information and A / B material and solvent usage.

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GEMS Markets and Applications

APPLICATIONS

Off Road and Earth Moving Vehicles

Aerospace / Aviation

Fork Lift, Trucks and Trailer

General Industry

Agricultural Machinery

Plastic Components

Transportation

Plus Many Others:

SUITABLE FOR MATERIALS

Solvent or Waterborne Coatings

Polyurethanes / Acrylics

Isocyanates / Epoxies

3


CAPABILITIES OF GEMS from BINKS PNEUMATIC SYSTEM ONLY

5 COLORS MAXIMUM

1 CATALYST MAXIMUM

NO Flowmeter

NO flushing of the catalyst pump required

RATIO from 1:1 to 100:1

SUPPORTS minimum flow rate of catalyst of 2 cc /

min

ACCURACY : +/- 1 %

FLUSHING PROGRAM USES AIR/SOLVENT

IN ORDER to SAVE UP to 60 % solvent


Asking The Right Questions 1. Find a customer – Leads provided by distribution, trade shows,

coating companies, online resources, industry magazines

2. Understand the customer’s processes – Watch, Question and

examine using Greenspray and observations

3. Uncover potential issues/pains/inefficiencies by listening to

sprayers and the paint shop staff

4. Understand how fixing their inefficiencies can make them

money or bring them other alternative benefits

5. Place a monetary value on the improvements

6. Quote the equipment including relevant accessories

7. Construct a ROI analysis and payback proposal

8. Install the equipment using ‘Out of the Box’ manuals, videos

and training presentations

9. Startup GEMS & spend time understanding GEMS and the way it

functions

10. Construct an Equipment Preventative Maintenance Schedule

based upon the customers work patterns, procedures and

production times


SIDE B CATALYST

SIDE A RESIN /

BASE

COLOR

MIXING

MANIFOLD


SIDE A RESIN /

BASE

COLOR

SIDE B CATALYST

MIXING

MANIFOLD


HOW DOES THE GEMS WORK ?


Fluid Supply

Pressure feed

tanks

DX70 1:1

DX200

1:1

MAPLE

3:1

MX L12/05

5:1 SYSTEM FOR

PNEUMATIC

GUNS

ONLY !

GEMS


Solvent/Air FLUSHING

Solvent ONLY flushing sequence

IMPORTANT

The catalyst

pump (‘B’

side) is

never

flushed!

Optional SOLVENT

flowmeter

‘Solvent-Air’ flushing sequence

= SAVES UP TO

LEAST

60% SOLVENT


GEMS SCREEN – EASILY

UNDERSTOOD ICONS


Very

simple, in

3 steps…

Example COLOR CHANGE with GEMS


Production Job Data


Color Change Job Data


Diagnosing An Alarm

Quick,

Simple

Efficient…

No alarm codes

(i.e. E27, etc….)

16 clearly defined

alarms

Description of the

fault and explanation

of the possible

solutions


Transfering Job Data

Ethernet

Port

(Standard)

Via Wifi Router

(Optional)

+ 100 000 JOBS

stored !

USB Stick (Standard)

job.csv

Statistics for

the job

job.log System Setting

& Alarms for the

job

alarms.log

Alarms record

since day #1

sysconfig.ini System settings

& machine totals


Data Collection

Which spray booth runs the most production?

Which painter uses the most material?

Why does one spray booth go through so much

more solvent?

Why does one spray booth get more alarms?

Which spray booth performs the best color

changes?


Standard Competitor Data Analysis

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Painter 1 Painter 2 Painter 3 Painter 4

Colour 1 Total Usage 15867 cc 16854 cc 15800 cc 17600 cc

# of Alarms 14 0 6 0

Total Solvent Usage 11520 cc 3264 cc 5290 cc 4800 cc


GEMS Data Analysis

Painter 1 Painter 2 Painter 3 Painter 4

Colour 1 Total Usage 15867 cc 16854 cc 15800 cc 17600 cc

# of Alarms 14 0 6 0

Total Solvent Usage 11520 cc 3264 cc 5290 cc 4800 cc

Colour 1 Gun Average Flow Rate 264 cc/min 211 cc/min 226 cc/min 220 cc/min

Total Gun Air time 7680 sec 2.13 hr 4896 sec 1.36 hr 4950 1.36 hr 4120 sec 1.14 hr

Total Gun Air + Fluid time 3040 sec 1.07 hr 4800 sec 1.33 hr 4900 sec 1.36 hr 4000 sec 1.11 hr

Average Gun spray time per part 640 sec 10.7 min 600 sec 10 min 700 sec 11.7 min 500 sec 8.3 min

# of Triggers 210 240 50 300

# of colour changes 18 4 6 2

# of successful colour changes 7 4 5 2

# of unsuccessful colour changes 11 0 1 0

Average Colour change time 62 sec 1.03 min 135 sec 2.25 min 180 sec 3 min 285 sec 4.25 min

Average Colour change Gun Trigger 60 sec 1 min 90 sec 1.5 min 120 sec 2 min 105 1.75min

Average solvent usage per colour change 640 cc 816 cc 865 cc 820 cc

# of components painted 6 8 7 8

Average Paint usage per Component 2644 cc 2107 cc 2257 cc 2200 cc

Total Job Run time 32400

sec 9 hr 32400 sec 9 hr 21600

sec 6 hr 32400

sec 9 hr

Thanks to information from the GEMS, it is easy to see the difference between sprayers


Paint Used / JOB

+

Number of alarms

Data Analysis Using Excel


Qty of paint & Qty solvent lost per color

In red : total losses



Total emissions of COV



TOTAL COST

OF A JOB.



RESULTS AFTER

INSTALLATION

• 52 engines / week

• 2’500 Litres paint per year

• VOC reduction approx

53% • Product flow rate 150-200 cc/min

• Mixing ratio 5:1

• Pot Life 8h at 20°c

• Process 2 layers

• Agitation of all colours & the

primer

Case Study

MANUFACTURER

OF BOAT

ENGINES


Optional Accessories

ADDITIONNAL

OPTIONS

FOR THE

GEMS

Dispense Pump Flow Sensor

What's it for? To monitor that there is material in the ‘B’ side

feed

Can you trust your operators to monitor reservoir levels?

360 degree Stack Light

Visible reassurance of the GEMS status if you can’t

see the screen or hear the alarm.

Air Cut Off Valve

Prevents atomisation of solvent and paint during loading,

flushing and colour changes

Gun Flush Box

Free up the operator during these

operations to do something more

productive

Gun Add-on Kit

What's it for? Allows GEMS to

control a second gun

Allows data recording for later

analysis


Graco 2KE - Operation System Appearance

First impressions matter.

Systems need to appear

friendly and simple to make an

easy transition for the

customer.

Screen Size & Capability

User experience and ease of

use is important. Learning how

to operate equipment needs to

be easy and straightforward.

Think about new employees

and training days.

3” Single Colour 7” Colour Touchscreen

Material Load/Installation

Screen

During installation and when air

is introduced into the material

lines, the system must be

easily primed to minimise

downtime.


Graco 2KE - Operation On Screen Instructions

Downtime is costly. Equipment

that helps the operator without

a manual can lessen downtime. No

On Screen Troubleshooting

Error codes add complication

to the troubleshooting process

and which equipment is the

root cause of the downtime.

No

Error Codes Only

Flushing Sequence /

Wastage

Programmable flush sequence

enables a typical customer to

observe a solvent reduction of

over 65%. During the flush the

mixing equipment will generate

an amount of waste.

Solvent Only Flush

Mixing Equipment Generates

120cc Waste

Solvent/Air Chop

Programmable Flush

GEMS Equipment Generates

20cc Waste


Graco 2KE - Maintenance

No. Of Parts In Mix Manifold

Number of parts exposed to

fluid stream must be minimised.

Reduce spares stock and

replacement costs.

23 parts 11 parts

B Side Flushing

When the B side is flushed,

solvent can contain moisture

and be incompatible with the

catalyst leading to

crystallisation and downtime.

Required Not Required

Visual Fluid Panel Material

Detection

When an issue occurs, systems

need to be easily analysed for

air bubbles, material present

and proper colour was loaded.

No Yes

5 Locations


Graco 2KE Data

USB Data Tracking

Expandable data storage and

universal data transfer away

from the machine.

Optional Cost Extra As Standard

Ethernet Connectivity

Non intrusive, easy data export No As Standard

Data Capabilities

Knowing information about

material and solvent usage can

lead to less wastage, VOC

reduction, accurate production

costings and labour costs.

Material Usage

Solvent Usage

Total Solvent Usage

No. Of Alarms

Sprayer Material Usage

Sprayer Avg. Material Flow Rate Per

Minute

Spraying Times (Labour Utilisation)

Sprayer Gun Triggers

Job Creation & Stop Times

Alarm History With Time Stamps

Full System Settings & Value Changes

To Configurations

A:B Usage For Each Colour

Actual Calculated Ratio

Total Material Usage

Total Solvent Usage

Successful Colour Usage

Unsuccessful Colour Changes

Avg. Colour Change Time Analysis

Last Colour Change Time Analysis


Wagner Flexcontrol

Data USB Data Tracking



from the machine.

As Standard As Standard


Non intrusive, easy data export No As Standard

Data Capabilities











VOC (Solvent) Quantities



Minute






To Configurations




Total Solvent Usage






Kremlin Cyclomix Micro

Data USB Data Tracking



from the machine.

None As Standard


Non intrusive, easy data export No – USB/Serial Via

Hyperterminal As Standard

Data Capabilities







Total Solvent Usage



Minute






To Configurations




Total Solvent Usage






Year 1 Value

$768,900

€708,206

£516,237

TCO

TCO

GEMS: The equipment and solution for Wood Polyester Coating

Technology

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