Reduce powder consumption

Reduce powder consumption

Avoid excess powder on the pieces with a more even film thickness and reduce the powder loss in the recovery system.

Gema knows that reducing the powder usage is one of the most crucial objectives in each powder coating line.

Many different elements are essential to achieve this important goal:

  • The best transfer efficiency to reduce the amount of powder that is recirculated in the recovery system.
  • An even film thickness distribution to avoid applying too much powder on the objects.
  • Smart automation tools to make sure that overspray is reduced and that each part is coated with the best application program.
  • A quick and efficient color change process to recover powder even for very small batches.
  • An efficient recovery system to reduce the amount of waste powder.

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Main Features Overview

    Part detection systems: quality and savings

    Part detection systems: quality and savings

    Automatic guns positioning, triggering and setting improve finishing quality and reduce powder wasted in the recovery system.

    More powder on the parts, less in the recovery

    More powder on the parts, less in the recovery

    The powerful 100 kV cascade and the advanced electrostatic controls ensure the highest transfer efficiency even with challenging powders.

    Always apply the right amount of powder

    Always apply the right amount of powder

    The patented DVC technology ensures precise and reproducible powder output regulations and improves the film thickness consistency.

    Coat each part with the right parameters

    Coat each part with the right parameters

    It's easy to store and recall your application programs and to automate the gun triggering and positioning depending on the object to coat.

    OptiSpray AP01 Application Pump: the revolution in powder feed

    OptiSpray AP01 Application Pump: the revolution in powder feed

    The best coating results are maintained constant for a very long period of time, even with longer powder hoses and higher powder output.

    Reduce spray to waste after color change

    Reduce spray to waste after color change

    The Magic System concept allows the powder recovery even for short production batches of different colors.

Case Studies

    Case Study Heating Cooling Sanitary: Air filtration

    Case Study Heating Cooling Sanitary: Air filtration

    Mikropor - Reduced powder consumption and higher production flexibility with MagicCompact EquiFlow BA04 booth, vertical reciprocator type ZA07, MagicControl CM30 system control, OptiCenter OC02 powder management with ultrasonic sieve US06 and OptiFlow IG06 injectors.

    Case Study Metallic Furniture: Shelving Racking ( HARTING Systems )

    Case Study Metallic Furniture: Shelving Racking ( HARTING Systems )

    HARTING Systems - High process stability and significant powder savings with OptiCenter OC03 powder center with OptiSpray AP01 application pumps, vertical reciprocator type ZA07, OptiGun GA03 automatic guns, OptiFlex Automatic cabinet and MagicControl CM30 system.

    Case Study Job Coating ( JIT Powder Coating )

    Case Study Job Coating ( JIT Powder Coating )

    JIT Powder Coating - Improved film thickness control and flexible color changes with MagicCompact EquiFlow BA04 booth, OptiCenter OC04, MagicControl CM30 and OptiGun GA03 automatic guns.

    Case Study Architecture ( Burgaud )

    Case Study Architecture ( Burgaud )

    Burgaud - Upgrade of an existing installation for more coating quality and powder savings with OptiStar CG08 gun control, OptiGun GA03 automatic guns with SuperCorona and OptiFlow IG06 injectors.

    Case Study Architecture ( KSM Production )

    Case Study Architecture ( KSM Production )

    KSM Production - Frequent color changes and high powder savings with OptiCenter OC03 with OptiSpray AP01 application pump, OptiGun GA03 automatic gun, OptiSelect GM03 manual gun and MagicControl CM30 system control.

    Case Study Job Coating (QPC Quality Powder Coating)

    Case Study Job Coating (QPC Quality Powder Coating)

    QPC Quality Powder Coating - More production flexibility and efficiency with MagicCompact EquiFlow BA04 booth, OptiCenter OC03 powder management with OptiSpray AP01 application pump, Gun axis UA04 with Dynamic Contour Detection and MagicControl CM30 control System.

    Case Study Architecture: Aluminum Profiles ( Extrual )

    Case Study Architecture: Aluminum Profiles ( Extrual )

    Extrual - Powder savings and improved productivity with OptiCenter OC02 powder management with Ultrasonic Sieve UA06, OptiGun GA03 automatic gun, OptiFeed PP06 pump and MagicControl CM30 system control.

    Case Study Electrical Electronics: Lighting ( Fagerhult )

    Case Study Electrical Electronics: Lighting ( Fagerhult )

    Fagerhult - Quality improvements and reduced powder consumption with MagicCylinder booth, OptiCenter OC02 powder management, OptiGun GA03 automatic gun and MagicControl CM30 system control.

    Case Study Heating Cooling Sanitary: Fuel Tanks-Gas Storage ( Hokuei )

    Case Study Heating Cooling Sanitary: Fuel Tanks-Gas Storage ( Hokuei )

    Hokuei - Increased productivity and improved coating quality with OptiFlex automatic cabinet, OptiCenter OC02, Robotic Guns GA02, Classic Line Manual booth and OptiFlex2 B manual unit.

    Case Study Automotive: Car Body ( Jiang Huai )

    Case Study Automotive: Car Body ( Jiang Huai )

    Jiang Huai - Convert from wet paint to powder and perfect coating results even with complicated parts with MagicCompact booth, OptiGun automatic gun, OptiSelect manual gun, MagicControl CM30 and OptiCenter.

    Case Study: Automotive ( Veriplast )

    Case Study: Automotive ( Veriplast )

    Veriplast - Constant film thickness and powder savings with MagicCompact EquiFlow booth, OptiCenter OC03 with OptiSpray AP01 and MagicControl CM30.

    Case Study Architecture: Aluminum Profiles ( Fu Jian Fen An )

    Case Study Architecture: Aluminum Profiles ( Fu Jian Fen An )

    Fu Jian Fen An - Improved Quality and powder savings for vertical coating of profiles with OptiGun GA03 automatic gun, OptiCenter OC02 powder management and OptiFlex Automatic control cabinets.

    Case Study Machine Industry: Agricultural Machines

    Case Study Machine Industry: Agricultural Machines

    Perfect Coating of XXL parts and quick color changes with MagicCompact EquiFlow XXL booth, MagicControl CM30, OptiCenter OC02, OptiGun GA03, OptiSelect GM03 and OptiFeed BigBag.

    Case Study Architecture: Aluminum Profiles ( Senior Architectural Systems )

    Case Study Architecture: Aluminum Profiles ( Senior Architectural Systems )

    Senior Architectural Systems - Quick Color change and repeatable coating results with MagicCompact EquiFlow BA04 booth, OptiCenter OC03 with OptiSpray AP01 and MagicControl system control.

    Case Study Metallic Furniture: Shelving Racking ( HNP Metalltechnik )

    Case Study Metallic Furniture: Shelving Racking ( HNP Metalltechnik )

    HNP Metalltechnik - Retrofit of an existing line for capacity increase and powder savings with OptiCenter OC02, OptiFlex Automatic AS08, OptiGun Automatic Gun, Vertical Reciprocators and MagicControl CM30.

    Case Study Metallic Furniture ( Li Geng )

    Case Study Metallic Furniture ( Li Geng )

    Li Geng - Powder savings of up to 50% and color change improvements with MagicCompact EquiFlow booth, OptiCenter OC02, OptiGun automatic gun, vertical reciprocators and MagicControl CM30 system control.

    Case Study Automotive: Wheels ( Cromodora )

    Case Study Automotive: Wheels ( Cromodora )

    Cromodora - Powder savings, constant film thickness and excellent surface finish with OptiCenter OC02 with Ultrasonic sieve, OptiCenter OC05 with OptiSpray AP01 application pump, OptiGun GA03, MagicControl CM30 and light barrier.

    Case Study MDF ( Ramseier Woodcoat )

    Case Study MDF ( Ramseier Woodcoat )

    Ramseier Woodcoat - Repeatable coating results and improved productivity with OptiSpray AP01 Application Pump, OptiGun Automatic Gun, OptiStar Gun Control, Vertical Reciprocators and MagicControl CM30.

    Case Study: Job Coating ( L. Schulte )

    Case Study: Job Coating ( L. Schulte )

    L. Schulte - Higher coating quality, quick color change and enhanced production flexibility with MagicCompact EquiFlow booth BA04 configured for manual coating with OptiFlex2 W and OptiCenter OC02 powder management system with ultrasonic sieve.

    Case Study: Automotive ( Metafin )

    Case Study: Automotive ( Metafin )

    Metafin - Coating line upgrade ensures powder waste reduction and annual cost savings with MagicCylinder EquiFlow booth QCS04, OptiCenter powder management, OptiGun automatic guns and MagicControl CM30 system control.

    Case Study Machine Industry: Production Machinery ( Ukai )

    Case Study Machine Industry: Production Machinery ( Ukai )

    Ukai - Powder Savings and increased application performance with MagicCompact EquiFlow BA03 booth, OptiGun GA03 automatic gun, OptiFlex Automatic control cabinet and OptiFlex2 B manual unit.

    Case Study: Job Coating ( SMP )

    Case Study: Job Coating ( SMP )

    SMP - Powder savings and easy color changes with OptiFlex2 S manual unit, OptiSelect GM03 manual gun and injector IG06.

Resources

    AP01 coating quality and powder savings Learn More File

    AP01 color change Learn More File

    Best Guns for Color Change Learn More File

    DVC Technology Learn More File

    Gun Nozzles Learn More File

    OptiFlex® Automatic Brochure

    OptiGun® GA03 System overview Brochure

    OptiSpray AP01 Brochure

    PCC and SuperCorona Learn More File

    Reciprocators and axes Brochure

    Reciprocators and axes Brochure

    SuperCorona® Data Sheet