Powder pumps are already in use for electrostatic powder coating. However the technologically complex design and high maintenance requirements of these pumps has so far prevented the success of powder pumps within the market.
Gema Switzerland GmbH (PaintExpo, Karlsruhe, 8 - 11 April, Hall 2 - Stand 2530) has successfully used powder pumps for a long time for transporting powder inside coating systems. Based on that extensive experience Gema has developed a new type of powder pump, the OptiSpray AP01. This pump is specifically designed for users that need constant and reproducible coating quality during multi-shift operations.
"While developing the OptiSpray AP01 we had the specific demands of manufacturers of aluminum profiles, big parts, white goods and automotive parts in mind. The new application pump is specially suitable for applications which have a high powder consumption, long hose lengths or that need constant coating quality over long production cycles. For all other application areas the injector technology will still be our first choice for transporting powder to the gun", explains Roman Mlakar, Product Manager at Gema Switzerland GmbH.
Space saving design and low maintenance effort
A significant characteristic of the application pump OptiSpray AP01 is the extraordinary slim design. The pump requires only as much space as an injector, which enables a space-saving system integration. Currently OptiSpray AP01 is the most compact model on the market and can be installed horizontally or vertically.
OptiSpray AP01 outperforms competitive products in many other ways. "While developing this product we specially focused on a constant powder output. Other technologies need daily adjustments because of wear parts. For the OptiSpray AP01 we eliminated such wear parts. Therefore the new technology enables highest reproducibility of coating results over long durations", says Roman Mlakar.
More productivity and gentle powder transport
The OptiSpray AP01 uses the SIT principle (Smart Inline Technology) developed by Gema.
The Inline Technology implies that the whole powder flow is absolutely linear. In contrast to other systems, which redirect the powder inside the pump up to 180 degrees, SIT enables a gentle powder transport and a clean and simple color change. Thanks to the low transport speed, difficult powder types can be transported gently and as a result the powder quality remains unaffected during the transport process.
Due to the compact integration into the new powder management system OptiCenter OC03 in combination with the very short suction tubes, a significantly improved constant powder output from 50-300gr/min is achieved.
By directly adding air at the OptiGun GA03-P, the powder cloud can be precisely adjusted and controlled. This is exactly what users with high quality demands require.
As a consequence of the consistent powder output powder savings of up to 15% can be achieved.
In conclusion the powder pump OptiSpray AP01 is a successful and versatile component in order to increase the productivity of powder coating systems.
The new powder application system OptiSpray AP01 has been in use for several months at the production site of one of the biggest furniture manufacturers in Europe. The customer has thoroughly tested the new product and confirms that powder handling and maintenance is extremely positive after 6 months of system operation. "We achieved a constant powder output, consistent film thicknesses and reproducible coating results over the whole time period. This guarantees us a constant coating quality, which we need as a manufacturer of furniture in the premium segment", confirms the Head of the Coating Department.
The new generation of Gema application systems – consisting of the powder management system OptiCenter OC03, the fully integrated OptiSpray AP01 powder pump, the Gun Control OptiStar CG12-P as well as the new automatic gun OptiGun GA03-P - convinces with the compact and space-saving design.
The new Gema automatic products – whether application pump or injector -present the same identical operating concept and product design.
In combination with the modern quick color change booth MagicCompact with EquiFlow Technology, the Gema system offers a stable powder output, consistent film thickness, reproducible coating results and a fast and clean color change. Users that need a high productivity and constant coating quality solution over long production durations will strongly benefit from the new Gema automatic generation.