Get More at Electrocoat 2006
March 4, 2006
Electrocoat 2006 is a learning event for the entire finishing community. Value and return on investment are a top priority to the association, so it has incorporated several enhancements to give you more.
Electrocoat 2006 returns to Orlando on April 19, 2006, and will be held at the Caribe Royale Resort & Convention Center. The three-day event will offer nearly 40 conference sessions and workshops, networking events and supplier-sponsored exhibit rooms (formerly called hospitality suites). The technical presentations are designed to provide relevant, need-to-know topics that electrocoaters can put to immediate use.
Electrocoat 2006 is a learning event for the entire finishing community. Conference sessions cover a range of topics, including the exploration of electrocoating technologies, evaluation of different e-coat systems, alternative processes, emerging technologies, performance requirements, environmental management and more. Workshop discussions enable electrocoaters to address specific business needs while supplier exhibits offer attendees direct access to technical updates, new equipment, chemicals, paint, ancillary equipment and finishing applications.
Value and return on investment are a top priority to the association, so it has incorporated several enhancements to give you more. This year's theme is "Get More!" and the event is offering just that. Three pre-conference workshops cater to the specific needs of people new to the industry, finishing line managers and executives. Additionally, there are extended hours for one-on-one meetings within the exhibit rooms. A keynote presentation will cover the history and global future of e-coat. And, conveniently, all conference activities will be on the hotel property.
Wednesday, April 198:00 to 9:00 a.m.
Pre-Conference Workshops (run concurrently)
E-Coat Boot Camp
Facilitator: William Radak, Valspar Corp.
Designed for people entering the industry and for those who want a refresher about electrocoating, this workshop provides a walk-through of an e-coat operation from beginning to end and touches on types of e-coat, pretreatment, material handling, system components and curing. Questions will be answered throughout the presentation.
Leading the Way To Innovation and Expansion
Facilitator: Kathy Follet, PPG Industries
An internal focus on daily operations is what finishing managers are all about. This discussion pertains to communicating at the multiple and necessary levels to initiate growth of your bottom line. This session will take a 10,000 ft. view of a finishing facility and focus on topics such as cost, quality, employee training, environmental management and productivity. Conversation is highly encouraged.
The Heat Is On: Hot Topics for Heavy Hitters
Facilitator: Jeff Oravitz, MetoKote Corp.
This interactive session invites senior level executives to discuss big-picture issues such as trends in U.S. manufacturing and business, the global climate, technology, people and accessing capital. This group views the industry at 30,000 ft. and has executive decision making authority.
9:00 to 9:15 a.m.
Welcome to Electrocoat 2006
Donald G.Kline, publisher, Products Finishing magazine
John Martin, PPG Industries, and president of The Electrocoat Association
9:15 to 10:15 a.m.
Global Challenges for Electrocoating Growth
Phil G. Phillips, managing partner, Chemark Consulting Group Inc.
Electrocoat growth in the industrialized regions of the world took a surprisingly long time to reach "adolescence" and to become a standard tool of use in today's finishing industries. Chemark will touch on its history and where e-coat came from and, most importantly, its future, where it is headed and compare it to alternative direct and indirect competitive coating systems.
Material Handling - Moving in the Right Direction
Moderator: Steve Church, George Koch Sons LLC
10:15 to 10:30 a.m.
Getting More Out of Your Monorail Conveyors
Ed Diekmann, George Koch Sons LLC
Following a brief description of the various monorail and power-and-free conveyors available to the user, a discussion of integrating the conveyor with robots in the load/ unload areas will be included. Finally, a brief description of the importance of maintaining your conveyor is included.
10:30 to 10:45 a.m.
Square Transfer Indexing Electrocoat Systems
Jim Miller, Therma-Tron-X Inc.
Matching equipment capabilities with product, process and facility demands are important considerations in weighing the advantages and disadvantages of square transfer indexing electrocoat systems. Although no one system type is superior in all electrocoating operations, square transfer indexing systems can, in many cases, offer the electrocoater several advantages in terms of floor space usage, tank charge costs, capital and operational expenditures, and pretreatment options.
10:45 to 11:00 a.m.
Programmable Hoist Electrocoat Finishing Systems
Jeff Wienke, Eisenmann Corp.
Programmable hoist systems are ideal for all part types requiring a multiple dip process and are very efficient in handling large parts in a compact footprint. Hoist systems can also be programmed with multiple process sequences and are easily interfaced with other conveyor systems for a variety of system layout options.
11:00 to 11:15 a.m.
Important Aspects of E-Coat Tooling
Anthony Sossi, ITD Precision
Developing the right kind of tooling (hangers and racks) is critical in order for parts to achieve a sufficient and consistent electrical charge throughout the e-coat process. Types of tooling designs will be discussed along with maintenance, material flow issues and how tooling design plays an important role in optimizing efficiency.
11:15 to 11:25 a.m - Q&A
You're Not E-Coating Metal; You're E-Coating Pretreatment!
Moderator: Chris Kankiewicz, Whiting Door Manufacturing Corp.
11:25 to 11:45 a.m.
Pretreatment: The Right Process For the Right Application
Randy Brent, PPG Industries
Do you understand how the pretreatment chemistry works in harmony with the electrocoat application? Many of today's new pretreatments provide more then just an inert anchor for paint. Chemically reactable products have opened the door to ambient temperature processing and huge potential energy savings. The question remains are these new pretreatments applicable for use in your system with your parts and metal mix? This discussion will provide you with an understanding of how to make the proper product selections and what the trade offs may be in performance and benefits.
11:45 a.m. to 12:05 p.m.
Emerging Technologies in Pretreatment
Terry Giles, Henkel Technologies
As the finishing industry faces the increasing demand for key raw materials going overseas, the role of pretreatment in maintaining your competitive advantage cannot be overlooked. From increased fuel and energy costs to differing quality and grades of the substrates used, emerging pretreatment technologies can turn such challenges into benefits. No heat conversions coatings will be key technologies in the coming years; additionally, pretreatment technologies that can handle a wide array of substrate variation will alleviate material supply concerns and allow for alternate sourcing of key commodities.
12:05 to 12:15 p.m.-Q&A
12:15 to 1:15 p.m.
2006 Professional Achievement Luncheon
Join the Electrocoating Industry in celebrating the accomplishments and contributions of the 2006 award recipients. The George E.F. Brewer and Best End-User Paper Awards will be presented.
System Management - Get More Bang For Your Buck
Moderator: John Martin, PPG Industries
1:15 to 1:35 p.m.
Cost Controlling Principles in an Industrial Electrocoat Facility
Greg Cramer, Autocoat,LLC
This presentation focuses on everyday cost controls within an industrial electrocoat facility. It shows the hidden cost reduction of operating an industrial e-coat system, centering on operating cost reduction, rack efficiency, waste reduction and quality maintenance.
1:35 to 1:55 p.m.
Efficient Electrocoat Tank Operation
Joe Subda, DuPont Performance Coatings
Electrocoating is a very efficient process, but there is always room for improvement. The best place to start is with statistical process control (SPC) Learn what SPC is and how to apply it to your electrocoat system in an easy-to-follow, step-by-step format.
1:55 - 2:15 p.m.
Color Control in Electrocoat
William Lemons, PPG Industries
Understanding the factors that impact color in electrocoat paint is critical to optimizing and controlling appearance, and for maintaining a match to the color standard. Color theory and formulation considerations will be reviewed and several aspects of controlling color in electrocoat paint will be presented.
2:15 - 2:35 p.m.
A Defect-Free Paint Finish Starts With Defect-Free Electrocoat
Terry Taylor, Filter Specialists Inc.
Everyone in the automotive industry knows that a lustrous paint finish sells product; the disagreement comes as to how to achieve a clean, consistent finish. This presentation proposes that mechanically removing the majority of ferrous metal contaminants early in the phosphate pre-clean process reduces all defects in the paint surface; moreover, it is being accomplished in existing automotive plants.
2:50 to 3:10 p.m.
Maintaining Your E-Coat System
Dennis Reeder, Honda Manufacturing of Alabama
The e-coat operator's daily challenge to consistently produce good quality requires the proactive approach of maintaining the system over the reactive approach of simply operating the system.
3:10 to 3:30 p.m.
Ron Phillips, Hi-Tech Flexible Products Inc.
Custom masking: Expense or investment? Necessary evil or competitive advantage? This presentation of the many capabilities of custom masking for e-coat will serve as a myth-busting, eye-opening look at this versatile custom feature.
3:30 to 3:50 p.m.
Applications and Markets
For Clear Coatings
Randy Campbell, PPG Industries
The application of clear coatings has expanded beyond the traditional high-end decorative markets as the proliferation of electronics and demand for more personalized items has resulted in new, unique finishes on products. New coatings are being promoted for color as well as texture, and on many new, non-traditional substrates such as leather and vinyl. For many of these new finishes, a final, clear coating must be applied for decorative and/or functional purposes. Clear coating options and benefits for various application techniques are examined, and typical markets served by clear coats such as automotive, decorative, industrial, and consumer markets are discussed.
3:50 to 4:10 p.m.
Multi-Colored E-Coat System - A Cost Effective Approach
Lonnie Pillar, Valspar Corp.
As part of its ongoing efforts to compete against off-shore manufacturers, Ames True Temper continues to expand the utilization of its electrocoat system to meet its end-users' requirements, including the ability to coat in multiple colors. Ames has significantly reduced the time for color conversions to just a few minutes.
4:10 to 4:30 p.m. - Q&A
4:30 p.m. - Exhibit Rooms OpenM.
Electrocoat 2006 Exhibit Rooms offer attendees a venue to view the products and services of industry suppliers without the hassle of dealing with a typical trade show. Individual vendors set up shop in private rooms so attendees feel comfortable talking about specific concerns or needs. (See sidebar for a list of exhibitors as of press time.)
Thursday, April 20System Efficiency
Moderator: Nick Francisco, BASF Corp.
8:30 to 8:50 a.m.
The "How To" of a Metal Finishing Turnaround (Even If You're Still Making Money)
Matthew Kirchner, ABQC Corp.
Learn about an eight-step plan which, if applied diligently and enthusiastically by a capable management team, will result in the successful redirection of a metal finishing company, lead to a higher rate of profitability and secure the future of the organization.
8:50 to 9:10 a.m.
Adding Electrocoat Capabilities to an Existing Metal Stamping Facility
Darlene Lawrence, Choice Fabricators Inc.
Alabama-based Choice Fabricators Inc. shares the success it has had by painting parts in house, this investment has reduced costs and opened new avenues of revenue for the facility. The decision to add electrocoat capabilities will be discussed, as well as engineering concerns, chemistry and process monitoring techniques. Key findings will be presented.
9:10 to 9:30 a.m.
Controlling the Phosphate and E-Coat Process with Consistency
Tim Gillies, Harley-Davidson Motor Co.
Harley-Davidson Motor Co. has realized significant improvements in cost, quality and productivity through the installation and use of PPG's Accu- DAQTM System. This paper describes the lessons learned during the installation process, how this system changed the process and the benefits Harley-Davidson is gaining as a result.
9:30 to 9:50 a.m.
Adding E-Coat to an Existing Finishing Operation
Gloria Ender, Freedom Finishing
Freedom Finishing began powder coating zinc and aluminum die-castings in 1989. Increased competition and the loss of jobs to overseas shops eroded the company's business, so Freedom decided to add an e-coat line to the existing powder line. This bold move created new business and enabled the company to increase powder coating sales by 20 percent.
9:50 to 10:10 a.m.
Universal Electrocoat for Parts Applications
Robert Schiller, BASF Corp.
During the past several years there has been a proliferation of electrocoat products to meet unique specifications for various automotive parts and sub-assemblies, including engine cradles, small parts, springs, frames and service parts. Although various products meet some specifications, the broad performance requirements of the varied specifications have restricted the use of a single product for all applications until now. A unique technology now exists that meets all specifications within a single product.
10:10 to 10:20 a.m. - Q&A
Roses are Red - Are Yours?
Moderator: Fred Hess, UFS Corp.
10:20 to 10:40 a.m.
What's In Your Oven?
Brian Thebaud and Robin Peffer,
This discussion is focused on the relationship between the curing process and the performance of finished product. Baking electrocoat in a gas vs. electric oven can lead to differences in physical properties. These differences have been linked to the presence of NOx in the oven during cure.
10:40 to 11:00 a.m.
UV Light Treatment for Controlling Bacteria in E-Coat Systems
Bruce Urtz and Brian Essenmacher, DuPont Performance Coatings
The impact of ultraviolet light application on the bacteria load of one plant's deionized water system and the effect of UV light installation on overall bath infection rates at a number of plants using this technology will be examined.
11:00 to 11:20 a.m.
Combined Heat and Power and Your Curing Oven - Making the Most of Your Energy Dollars
Jay Johnson, Ingersoll-Rand
Investing in the efficiency of energy-intensive processes serves as a hedge against energy price volatility. For those with higher than average electricity rates, the integration of a combined heat and power (CHP) device can shave cost from the bottom line, and reduce their impact on the environment. This paper briefly describes one successful method, and some basic guidelines to consider.
11:20 to 11:30 a.m. - Q&A
12:30 p.m. - Exhibit Rooms Open
Friday, April 21New Developments
Moderator: Jon Nylen, Henkel
8:30 to 8:50 a.m.
Vario Shuttle - New Technology in Automotive Pretreatment and E-Coat
Richard Goelz, Eisenmann Corp.
Vario Shuttle utilizes a dual electrified monorail shuttle and provides an alternative to conventional pendulum conveyor systems. Significant advantages of the system and its various configurations are the topic of this discussion.
8:50 to 9:10 a.m.
Alternative Surface Preparation Method for E-Coat
Duane Fudge, GE Water & Process Technologies
This paper will review the performance characteristics of a next- generation surface treatment program.
9:10 to 9:30 a.m.
Building Your Own HMI SCADATM Process Control System
John Bougneit and Craig Henry, JP Tech
What is "HMI SCADA" and why use it? This process control system eliminates monitoring data by hand, uses standard software/hardware, and offers flexibility in accordance with needs and available resources.
9:30 to 9:50 a.m.
Module for Use With Low VOC,
High Edge E-Coat Paint
Mike Qusen, Sepro Inc.
Field test results of an alternative ultrafiltration (UF) module will be shared, in addition to a side-by side comparison of operational performance and life expectancy of conventional spiral elements vs. a high density module.
10:00 to 10:20 a.m.
A New UF System Concept for Spiral Wound Ultrafilter Elements
Jan Tump, Membracon Filtration B.V.
The concept discussed here includes a paint flow pattern in the UF element housing which enables the location of paint inlet and outlet manifolds, gauges and valves to be located conveniently for the operator and maintenance people. Coupled with reduced job engineering, it is an economical, efficient answer to age-old problems.
10:20 to 10:40 a.m.
New Developments in Bulk Finishes
Gary Orosz, PPG Industries
This presentation covers the unique features of an e-coat system that carries stacked parts through e-coat, cure and cooling continuously, thus eliminating the transfer to other belts, which can result in surface scatches and mars.
10:40 to 11:00 a.m.
Electrocoat for Automotive Fasteners
Duane Drobnich, Ford Motor Co.
Electrocoat applied to fasteners can improve corrosion resistance, achieve consistency of torque tension and maintain close tolerances for good fit requirements.
11:00 to 11:20 a.m.
Advanced Ultrafiltration Membranes Developed for Electrocoat Paint Recovery in the Automotive Industry
Gregory Choryhanna, Microdyn-Nadir
This discussion covers a recent demonstration in which newly developed Ultrafiltration (UF) membranes were employed to improve plant operations in the recovery of electrocoat paint. Conclusions and recommendations define how the new UF technology affects existing systems and impacts new equipment design for the recovery of electrocoat paint.
11:20 to 11:30 a.m. - Q&A
Noon - Conference Adjourns
For more information, contact Anne Von Moll, conference assistant, at 513-527-8800, ext. 298, or call 800-950-8020. Or, e-mail anne@ electrocoat.org.