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Nordson Prodigy® Powder Painting Solution Saves Refrigeration Manufacturer Nearly a Quarter of a Million Dollars in First Year of Use

Published on 2009-04-09. Author : SpecialChem

AMHERST, Ohio -- Nordson Corporation customer Kysor//Warren, a century-old manufacturer of refrigeration solutions for the supermarket industry, reports that it has realized annual savings of $225,000 related to efficiencies gained from the use of Nordson's Prodigy High-Density, Low-Velocity (HDLV) manual gun powder coating system.

Kysor//Warren (Columbia, GA) is a leading supplier of frozen, medium temperature and heated display merchandisers and mechanical refrigeration systems used by many major national and regional grocery chains. The company recently converted to a Nordson Prodigy system as it moved toward lean manufacturing operations. In its first year, Kysor/Warren attributed a savings of nearly a quarter of a million dollars to the Prodigy system, resulting from improved line density, material savings and increased productivity.

At Kysor//Warren, each refrigeration display case is manufactured and powder coated based on a custom order, which means 90 to 100 color changes on average during each two-shift day. The company offers approximately 150 colors with 40 or 50 different colors used regularly, and will add more colors as customers request them. At the time of conversion, Kysor//Warren had a 56-foot gap between parts for every manual color change. Its goals were to improve line density, increase production by coating 70 percent more units per week, and reduce spray-to-waste color changes.

The Prodigy manual spray system precisely dispenses powder coating for superior finish quality, less waste and fast color changes. Its innovative nozzle technology ensures a softer spray, larger fan pattern, even pattern distribution and less powder consumption. In addition, the combination of the Prodigy manual powder spray gun and controller and the Prodigy HDLV pump provides for higher transfer efficiency, higher powder output, and ultra-fast color change.

As a result, Kysor//Warren decreased its line spacing and picked-up an additional three hours of production time each day - without actually working three additional hours. The company also reduced wasted powder 25 percent. The HDLV technology is also helping Kysor//Warren achieve coating thicknesses consistently between 2 mils and 3 mils and one of the best lead times in the industry. It has also achieved a staggering 50 percent increase in production. "We've increased the number of color changes, which goes against what you'd normally want when focusing on lean production. But when you cut color change time by 70 percent, it works really well toward increasing production," explains Matt Goodson, paint technician, Kysor//Warren. The only fully integrated solution available to manufacturers today, the Prodigy system incorporates a HDLV high-capacity transfer pump, gun delivery pump and spray gun, offering high-performance material transport and application. Combining the benefits of a softer spray and less powder consumption with easy operation, many manufacturers have documented significant costs savings and more efficiency in their powder coating operations. The benefits of the Prodigy HDLV Manual Gun System include:

  • Less air in transport line for lower powder velocity and softer spray
  • Softer spray at gun tip for higher first pass transfer efficiency
  • Higher first pass transfer efficiency means greater powder savings
  • Softer spray with more powder means better coverage in cavities and corners
  • Paints faster at high line speeds with higher powder output
  • Purgeable design provides ultra-fast color change

About Nordson Corporation:

Nordson Corporation is one of the world's leading producers of precision dispensing equipment that applies adhesives, sealants and coatings to a broad range of consumer and industrial products during manufacturing operations. The company also manufactures equipment used in the testing and inspection of electronic components as well as technology-based systems used for curing and surface treatment processes. Headquartered in Westlake, Ohio, Nordson has more than 4,100 employees worldwide, and direct operations and sales support offices in 32 countries.

Source: Nordson Corporation

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