Power Up Your Productivity with the FirstPass Power™ Gun, OptiSelect®, part of ITW Gema's OptiFlex® Manual Powder Coating Series. Using 100,000 volts of FirstPass Power, you can coat it right the first time - every time. Minimize downtime, spray less powder, experience fewer rejects, and reduce labor costs with the OptiFlex!

• 100,000 volts of FirstPass Power gives you the ability to coat your parts right the first time – every time.
• OptiFlex "smart" technology stores your application settings for easy recall in any coating scenario.
• Quick, easy-to-learn procedures reduce training needed to turn operators into manual powder coating experts.
• "On-gun" remote controls adjust coating mode and powder delivery without requiring operators to turn away from their work.
• OptiStar® Advanced Control Unit provides total control flexibility, giving operators a choice between 20 custom programs and 3 preprogrammed settings.
• Patented Digital Valve Control (DVC), automatically and precisely adjusts all air required for powder coating.
• Advanced pump technology provides trouble-free, uniform powder delivery time after time.
  

The OptiSelect®

• OptiSelect Manual Powder Gun, with an integrated cascade producing 100,000 volts of FirstPass Power™, provides maximum charging at the tip.
• OptiSelect features "on-gun" remote control, letting operators conveniently select programs and adjust powder delivery.
• The gun weighs less than 19 ounces, reducing operator fatigue.
• Ergonomically designed handle provides more comfortable
  in-hand balance and feel for your operators.
• Isolated powder path ensures proper charging for all powders, including metallics.
• No powder tube to replace simplifies maintenance, reduces powder velocities, minimizes impact fusion, and enhances transfer efficiency.
• Field-proven, self-cleaning electrode ensures uniform powder particle charging, optimizing transfer efficiency.
• Removable nozzles and a quick-release powder hose connector make cleaning and color changeovers fast.
  

The OptiStar®

• OptiStar Advanced Control Unit offers custom and preprogrammed settings, giving you versatility for any application.
• For ultimate flexibility, 20 custom programs allow you to set powder output, air volume, current, and voltage, saving them for recall at any time.
• When a simpler solution is called for, operators can select one of OptiStar's 3 preprogrammed settings:
  Flat Parts, maximizes voltage for optimum transfer efficiency.
  Complicated Parts, modifies voltage while holding current for optimum penetration and transfer efficiency.
  Recoat Parts, automatically adjusts voltage and current to the optimum level for recoating previously coated parts.
• Within the OptiStar, the DVC automatically adjusts all air required for powder coating, keeping the system in control at all times.
• Rinse air selection buttons ensure correct air volume, keeping the electrode clean and maximizing transfer efficiency.
• Help code display simplifies operator troubleshooting.
  

The OptiFlow®

• Advanced engineering of OptiFlow High Performance Powder Pump ensures uniform powder delivery for every application.
• Keyed quick-disconnects facilitate fast installation and removal.
• Only one major wear part keeps spare parts and operational costs exceptionally low.
• Check valves and plug-in design promote reliability and easy maintenance.
• Precision-manufactured injector jet stays in place, assuring proper flow every time.
• Easy-to-clean design requires no disassembly for most color changes.

Why Should I Buy An OptiFlex?

• With ITW Gema's OptiFlex Series, you've got all you need to power up your productivity... right in the palm of your hand! From the OptiSelect Gun to the OptiStar Control Unit and OptiFlow Pump, every component of the system is designed for total reliability, convenience, and performance.
• Choose Fluidizer, Box, or Stirrer units. The result is always flexible and consistent high-quality coating of parts and products… with less effort, less operator training time, and fewer things to go wrong all
  along the way.
• So advanced that it's incredibly simple, the OptiFlex is truly the practical answer for manual powder coating.
• Service and Support. In addition to our unique five-year warranty, our products are supported by a dedicated service team. ServiceNet is our 24-hour nationwide network of engineers and factory-trained distributors ready to provide you with a high level of local support.

Manasquan, NJ – The world's first powder-coating and high speed-infrared curing system to be employed in the production of steel wiring trays (lintels) is reaping multiple benefits. The new finishing installation addresses environmental compliance issues and maintains productivity levels while substantially reducing floor space requirements.

Thermal Innovations Corporation, the US affiliate of TRIAB, a Swedish-based infrared equipment company located in Molndal, Sweden, were selected to design and install the upgraded finishing lines for a wiring tray (lintels) company, which are used in building and construction to support doors and windows. The centerpiece of the new system, and infrared-enhanced Speed Oven® curing oven, combines high-purity infrared technology with indirect gas-fired convection heating to provide a rapid but highly controlled energy transfer.

Nick Fusilli, Vice President of Engineering for Thermal Innovations Corporation, noted that the decision to pair a powder coating line with an infrared curing system was based on environmental concerns, as well as productivity and quality factors. "The strict regulatory environment in Europe has persuaded many manufacturers t replace solvent-based coatings with posers, eliminating the problem of VOC emissions. Bu using infrared-enhanced heating to accelerate the curing cycle, you don't sacrifice productivity, and you get better control over the process, " said Fusilli.

The Speed Oven system uses high-purity emitters that transmit energy of specific wavelengths directly to the wiring tray coating. The emitters can be adjusted to match the absorption characteristics of the coating, based on chemical composition. The infrared component of the system provides a quick temperature ramp-up, while the convection stage assures a fast, even cure.

New powder booths were supplied, Thermal Innovations designed a spray booth conveyor that requires minimal adjustment to the spray guns as lintel size is changed. The Speed Oven cures the powder in under 90 seconds at a temperature of 430 – 465°F. The line speed varies from 30-40ft/min, depending on part size. The entire production cycle, including formation, welding, coating and curing, is about four minutes long, compared with cure time of 20 minutes in a convection oven.

The new operation also includes a fully automated conveying system and a PLC-based control panel that can be adjusted to accommodate wiring trays of various types and sizes. With 27 different settings, the control gives them the ability to maintain temperature uniformity and regulate power consumption regardless of wiring tray thickness.

According to Fusilli, the success with powder and infrared curing can be easily translated to other application s in the construction and appliance industries in the United States, which has issued its own strict regulations curtailing solvent emissions. "Infrared technology is ideally suited to flat-line, two-dimensional, powder-coated applications," said Fusilli. "Appliance consoles come immediately to mind, and aluminum extrusions would also be a good fit."

Thermal Innovations Corporation designs, manufactures, and markets infrared heating equipment for the plastics, electronics, automotive, and industrial finishing markets. The Company is affiliated with TRIAB, a leading supplier of infrared systems to the European marketplace. For more information, contact Curt Leach, Thermal Innovations Corporation, 1.800.756.5772.

The efficient design of our DIAMOND™ Series coating booth makes the unit ready to install and begin production. No other side-draft cartridge collection booth is as easy to operate, while giving you exceptional performance with each and every application.

Simple to Install

• DIAMOND Series coating booths feature plug-and-play installation with a fully prewired and preplumbed booth base, which is shipped preassembled in most cases.
• Bolted construction makes the booth upper structure easy to assemble and modify.
• Installation time is reduced by up to 50%, and costs reduced by as much as 80%, compared to other unassembled booths.
• All power and interlock connections are made to one location for simplified installation.

Easy to Use

• Polycarbonate is an extremely durable plastic material that resists abrasion and scratching. The hard, slick surface of the DIAMOND Series booth stays smooth, clear and easy to clean.
• The cartridge collector assembly uses horizontally mounted filters easily accessed from outside the unit.
• Side-draft cartridge modules are interchangeable for fast and easy color changes.
• The mobile cartridge collector assembly features a single-point clamping device to ensure a tight fit. Minimal effort is required by the operator to change between collector assemblies during color change.
• When a fast color change is needed, two or more DIAMOND Series booths can be installed in a roll on/off format.
• Location of ancillary reclaim equipment is based on application need, not collector location.
• Collector opening is at floor level for easy removal of powder from the booth floor and for transfer back to the reclaim assembly.

Efficient Design

• Location of automatic gun slots, manual openings, the collector module and the aerodynamic design of the vestibules all contribute to maximize powder transfer efficiency.
• Clear polycarbonate panels provide the best possible lighting for product application.
• Complete visibility of spray operation is available at all times, allowing visual monitoring of both manual and automatic gun performance.
• Pressure drops are constantly monitored across the filters to maintain the utmost operating efficiency.
• Cabin structure is customized to meet specific application needs with our standard combination of clear and stainless steel structure, or the optional all-stainless steel configuration.
• Compact floor space design of collection equipment.
• All DIAMOND Series booth bases are designed to integrate into most standard systems without conveyor elevation changes from the pretreatment system.
• The center design incorporates air flow vestibules in each automatic gun slot, thus channeling the air flow around the gun and ensuring containment of oversprayed powder.
• Side draft collection unit provides uniform airflow while allowing operator to visually inspect the level of powder in the bottom of the collector.
• Direct drive fan provides uniform air volume performance over the full life of the cartridges.
• Booth ranks as quietest on the market (74 db).
• Low pressure, high volume back pulse reduces noise and improves cartridge life.

Outstanding Performance

• Cartridge filter design maximizes both life and powder recovery performance of the filters. It provides maximum filtration at the lowest possible pressure drop.
• Uniform disbursement of recovery air recycled through highly efficient safety filters under the booth prevents drafts that can compromise the environment.
• Unique filter eliminates need for "seasoning" at startup.
• Polycarbonate material reduces the amount of powder build-up on booth walls, allowing more powder to be attracted to the part, thus minimizing clean up.
• Aerodynamic side-draft design creates a superior application zone for repeatable performance.
• Open-face collector promotes uniform air flow and more consistent application performance.
• Efficient design features greater than 95% material utilization

Power Up Your Productivity with the FirstPass Power™ Gun, OptiGun®, part of ITW Gema's OptiFlex® Automatic Powder Coating Series. Using 100,000 volts of FirstPass Power, you can coat it right the first time - every time and optimize your automatic powder coating operation!

• 100,000 volts of FirstPass Power™ gives you the ability to coat your parts right the first time – every time.
• The OPTIFLEX Series improves profitability by making your operation more efficient.
• The simplified user interface gives operators total control flexibility without having to worry about balancing several different settings.
• Quick, easy-to-learn procedures reduce training requirements with operators.
• The OPTIFLEX Series decreases your down time by automating coating configurations.
• The OPTIFLEX's group of high-tech components are designed to save time in an XTreme Color Change Environment.™
• The intelligent automation and the latest powder coating technology increases transfer efficiency, reducing the amount of powder wasted.
• The OPTIFLEX Series improves productivity, even in more challenging applications such as porcelain enamel.

The OPTIGUN®

• OptiGun Automatic Powder Gun, with an integrated cascade power supply producing 100,000 volts of FirstPass Power™, provides maximum charging at the tip of the gun.
• ITW Gema's integrated cascade power supply provides maximum charging at the tip of the gun.
• Improved design ensures longer life and better reliability.
• Contoured-body design prevents powder from collecting, making cleaning easier.
• Sealed gun-body design stops powder from entering the internal cavity, eliminating potential voltage and color-change contamination problems.
• Improved cascade design no longer requires grease, which simplifies maintenance and repairability.
• Enlarged tube diameter provides softer spray patterns, allowing the electrostatics to have greater control and increased transfer efficiency.
• Quick-change hose connector and replaceable, threaded powder-tube enable quick removal and easy maintenance.
• Compatibility with all nozzles and extensions for the OptiSelect™ manual powder guns, simplifying replacement of wear parts.
• Optional Super Corona™ ring can be added to minimize orange peel and improve penetration.

The OPTISTAR®

• OPTISTAR's patented Digital Valve Control, (DVC) offers a new standard of precision and more uniform film thickness, resulting in lower operating costs
• Within the OPTISTAR, the DVC automatically adjusts all air required for powder coating, ensuring air flow accuracy to plus or minus 1%..
• Uniform volume control and industry-leading first-pass transfer efficiency saves powder, and results in a more consistent finish.
• Unmatched program storage capacity (up to 250) allows for fast recall of all settings for any application.
• Unprecedented control over voltage, current, electrode rinsing air, powder output, and air volume give you the ability to repeat quality performance–every time.
• Remote gun triggering and purging can be operated from the Programmable Logic Controller (PLC) or canbus serial protocol.
• OptiStar communicates with your PLC, allowing for advanced diagnostics and programmability.
• Optional Flow-Control Module™ for closed-loop control of the total air volume for consistent powder delivery and accuracy.
• Rinse air selection buttons ensure correct air volume, keeping the electrode clean, and maximizing transfer efficiency.
• Help code display simplifies operator troubleshooting.

The OPTIFLOW®

• Advanced engineering of OPTIFLOW™ High Performance Powder Pump ensures uniform powder delivery for every application.
• Keyed quick disconnects facilitate fast installation and removal.
• Only one major wear part keeps spare parts and operational costs exceptionally low.
• Check valves and plug-in design promote reliability and easy maintenance.
• Precision-manufactured injector jet stays in place, assuring proper flow every time.
• Easy-to-clean design requires no disassembly for most color changes.

Greater Skill - Greater Service - Greater Value

• When you partner with ITW Gema, you gain access to decades of application expertise and know-how. Unlike any company in our industry, ITW Gema spends significant time and money in the pre- and post-installation phases, working with our customers to ensure they are getting the most out of their ITW Gema powder coating system.
• Our team of experts will provide you with a comprehensive assessment of your finishing system requirements, informing you of opportunities to improve your efficiency and your bottom line. Using ITW Gema's proprietary software, we will examine your process requirements and goals to determine what system configuration will best meet your needs – and generate the highest return on investment.
• Once the system is installed, our experts spend time on-site measuring everything from film thickness to reclaim efficiency; testing your various substrates and parts; and adjusting your gun positions. They will synchronize your equipment to meet your production needs, while ensuring the system is operating at peak efficiency.
• In addition to an optimized powder coating system, ITW Gema provides advanced-level training. Our technicians will turn you and your staff into experts in the operation and maintenance of your equipment. We will also consult with you on an appropriate ServiceNet support plan to keep your system running like new for years to come.
• With ITW Gema, you don't just get industry-leading equipment...You get industry-leading equipment, support, and expertise. What else would you expect from the world leader in powder coating equipment.

What Makes the OPTIFLEX So Optimal?

• The OPTIFLEX's advanced technology combined with its easy-to-use interface leads to optimal results–every time.
• The flexibility of the OPTISTAR enables you to store your voltage, current, powder output, and air volume settings for up to 250 applications. Simply select the program number and you're ready to coat.
• The design of the OPTIGUN, with its quick-release connections, makes for easier and faster cleaning and maintenance allowing you to spend more time coating.
• Add the advanced and easy-to-maintain OPTIFLOW Pump to provide consistently uniform powder delivery–and your powder coating operation has just become optimized.
• What makes the OPTIFLEX so optimal? The intelligence, integration, and automation that only ITW Gema provides.
• Call an ITW Gema representative today at
  800-628-0601 to discover how the OPTIFLEX can help you.

The OPTIFLEX is Optimum for YOU.

• When you combine the OPTIGUN, the OPTISTAR, and the OPTIFLOW, you've just arrived at the future of powder coating. These three high-tech components deliver to you three important benefits: repeatability, results, and ROI.

ITW Gema's Magic Compact® powder coating system offers fast color changes, yet its compact design fits into any XTreme Color Change Environment.™

Lean manufacturing is a trend in many industries. Whether you are a lean operation or not, ITW Gema has equipment solutions that can provide higher productivity at a lower cost. One such example is ITW Gema's Magic Compact Series Powder Coating Booth!

The Magic Compact is designed for automatic powder coating with XTreme Color Change requirements. When required, manual stations can be added to the booth cabin, allowing operators to effectively apply powder to your products. Whether automatic, manual or both, the overall booth footprint of the Magic Compact is small and easy to use.

The Magic Compact booth incorporates all of ITW Gema's industry leading, field-proven technology, like the OptiGuns®, OptiStar® Advanced Control Units and Chameleon Color Management System™, and is more than capable of meeting the needs of your rapidly changing manufacturing environment. The Magic Compact is designed to be a fully integrated system that delivers the speed and flexibility needed to handle your frequent color changes.

Fast and Simple Color Change

The Magic Compact is a quick color change system. This is due in part to a compact booth design that reduces powder accumulation, making cleaning faster and easier. By integrating the Chameleon Color Management System, much of the cleaning process is automated and guarantees the highest quality color change. Training personnel is a painless process, after which, color changes can be carried out quickly with only one or two technicians. You can change colors so fast with a Magic Compact, you may not need another booth!

Built for XTreme Color Change Environments

Like all ITW Gema automatic powder coating booth systems, the Magic Compact is engineered for high performance and minimal powder consumption. Here's how it all comes together:

1. The Magic Compact is a platform for the the world's best powder coating guns... the OptiGun automatic series and the OptiSelect® manual series. Both guns feature 100,000 volts of FirstPass Power™ to allow you to coat your parts right the first time – every time. The guns have fewer wear parts than other manufacturers' guns and the self-cleaning electrode ensures uniform particle charging for optimal transfer efficiency.

2. The Luminaire™ plastic sandwich-wall booth surfaces are non-conductive to minimize powder accumulation in the cabin for a faster color changeover. Easy-access booth design allows an operator to quickly perform any manual cleaning procedures from outside the booth.

3. Seamless ductwork is maintenance-free and substantially minimizes the risk of color contamination. Magic Compact's advanced mono-cyclone has a built-in sieve that screens out contaminates, making clean-up a snap. Dense-phase transport technology, that uses less compressed air than traditional transfer pumps, offers improved material handling of the recovered powder from the cyclone to the Chameleon.

4. ITW Gema's patented Twin-Air Deck™ design keeps powder from accumulating on the floor. Coupling a uniform downdraft air flow across the entire floor, along with automatic cleaning of the booth floor, keeps powder in process. Color changes are performed quickly and easily!

5. Along with the Magic Compact, the integrated Chameleon Color Management System uses PLC intelligence to automate cleaning by pulsing compressed air over the gun exterior and throughout the powder path, including suction tubes, pumps, powder hose and gun. This process cleans so effectively that color contamination is virtually eliminated. The Chameleon also improves performance by allowing powder to be sprayed directly from the powder manufacturer's original shipping container. This minimizes the number of hoppers and dedicated equipment typically required to reclaim powder.

6. With a focus on automatic applications, the Magic Compact incorporates ITW Gema's newest control system, the OptiStar Advanced Control Unit. OptiStar offers individually programmable coating parameters for each gun. Tying the OptiStar controllers together is the OptiControl™ PC-based control system that automates the powder application equipment. OptiControl can recognize incoming parts and trigger guns in one of 3 automatic ways to apply powder to the parts uniformly, saving powder and minimizing operating costs. OptiControl can extend to other production systems as well, for absolute coordination of all coating processes. PC-based technology makes it easy to set up and use, requiring minimal training for the operators.

Find out more about the full line of Magic Series™ booths and the XTreme-Machines™ from someone who's actually using them now! Call your ITW Gema representative at 1-800-628-0601. And, if you'd like to participate in the Application Systems Analysis Program (ASAP™), we'll be glad to schedule your initial consultation at that time.*

*ITW Gema's ASAP (Application Systems Analysis Program) provides you with a comprehensive review of your finishing systems, informing you of opportunities that will improve your bottom line. After a thorough analysis of your operation, our representative will present a cost/benefit analysis customer-tailored to your needs, including anticipated return on your investment.

Over the past 25 years Therma-Tron-X, Inc. has installed numerous monorail systems throughout all of North America, including Canada and Mexico.

They have designed and developed SpiraFlow Technology for the monorail systems which offer many advantages to your coating needs, including:

• No inherent dead spots or settling of paint solids
• Proper circulation with a minimum of surface disturbance
• Elimination of damaging foam deposits
• Allows 100% draining capability for easier cleaning, maintenance and loose part removal.

The advantages of this technology optimized throwing power by enhancing circulation between the parts. Paint flow is split equally between dual circulation pumps, giving Therma-Tron-X monorail tanks up to three times the filtration rate of other electrocoating system.