Considering a Manual Conveyor? Conventional Batch Coating is Better
When specifying a new powder coating system, companies sometimes choose between a conventional batch powder coating solution or a manual conveyor-based one. By conventional batch coating, we mean using carts or rolling racks to move parts between appliances and hold parts in place while they are being coated and cured. A manual conveyor system requires an overhead rail or floor mounted track and a set of trolleys. Parts are held on hooks or carriers that are moved manually by workers, often by using a chain to pull the trolleys along the conveyor. While both approaches have their merits, conventional batch powder coating is consistently a more versatile and cost-effective option, especially for businesses with limited floor space.
Here are the 5 key reasons why conventional batch powder coating is better than using a manual conveyor system:
1. Flexibility
One of the primary advantages of batch powder coating is its flexibility. Batch systems are designed to accommodate a wide variety of part sizes, shapes, and volumes. Whether you’re coating small, uniform components or large, irregularly shaped items, a conventional batch system can accommodate any and all parts that fit properly inside the booth and oven. In contrast, conveyor systems are typically limited by the location and configuration of the conveyor track or overhead rail (which is usually located in the center of the appliances), making it challenging to coat oversized or uniquely shaped items that may need to be positioned off-center.
For businesses that take on custom jobs or have fluctuating production volumes, batch powder coating allows for quick adjustments because different types of racks can be used. An added benefit is that projects that encounter a hiccup can be moved to the side. This isn’t possible with manual conveyor: a problem with one process impacts all the processes! As an example, let’s say the power goes out for a moment during a storm and the oven’s safety system shuts it down. With a batch system, the powder booth operator can continue to coat and simply move carts of parts to an empty spot on the shop floor once they are coated. With a conveyor system, once the space between the oven and booth is filled with parts, the coater can no longer continue working if the oven is down. Another example would be an unplanned rush job that has to go out ASAP. Until the parts that are already loaded are cleared from the conveyor, the rush job can’t get done.
We should also mention safety concerns and how they impact both cost and versatility. With conveyor systems, the parts are loaded onto hooks or carriers or some combination of both. The parts are removed once they have been processed. The same approach applies when using carts. One big difference is that the location of these operations is fixed when you use a conveyor but can be refined or changed temporarily when using carts. There’s also the issue of the travel path. Not only can parts hanging from an overhead conveyor block foot traffic or prevent forklifts and similar equipment from being able to move through the coating area, regulations or plant safety policies may require the installation of guards to protect personnel and equipment if a part falls from the conveyor. All of these factors can increase costs, reduce flexibility, and have a negative impact on productivity.
2. Lower Cost
Even without considering safety constraints, batch powder coating systems are far more affordable to purchase and install than conveyor systems. Conveyor setups require significant infrastructure, including conveyor supports and custom rails or tracks. Additionally, ovens and booths will require custom features such as cut-outs in the doors or enclosures that allow the conveyor rail to pass through. The booths and ovens are also usually larger than when using carts because there needs to be room to fit the conveyor supports. The appliances may need to be built with doors at both ends to accommodate the workflow through them. These features, plus the cost of the conveyor itself, combined with the added installation costs, can significantly increase the total acquisition budget.
This increase scales up as the system becomes more complex. If you intend to use chemical pretreatment and dry the parts before they’re coated, the cost will be even higher than if you choose a conventional batch approach. Not only will you need more conveyor, there is no convenient way to use your curing oven for drying wet parts unless you spend extra for a truly custom oven design and a much more sophisticated conveyor. In addition, the conveyor section that passes through the pretreatment system will need to be stainless steel to avoid corrosion–adding even more to the initial cost.
As we mentioned above, any breakdown in the conveyor line can halt production entirely, reducing efficiency and adding to operational costs.
In contrast, batch systems require minimal infrastructure. A basic batch setup includes a spray booth, a curing oven that can also be used to dry parts, a pretreatment spray wand, wash area or enclosure, and a powder spray gun, all of which are relatively affordable. Carts or rolling racks can be purchased or built as they are needed. There’s no customization or upgrades needed for the appliances and there’s no expense for conveyor, supports, or conveyor installation. For small and mid-sized companies or start-ups, this lower capital expenditure makes conventional batch powder coating systems a more accessible option.
3. Throughput
Batch powder coating excels in low to medium volume production scenarios, making it an ideal choice for manufacturers and coating shops that value versatility over maximum throughput. Custom fabrication shops, “job shop” coaters, and manufacturers of specialty products can all benefit from the flexibility and scalability of batch systems.
Manual conveyor systems, on the other hand, may be limited to more consistent parts profiles and their production volume is usually equal to or less than what can be attained with conventional batch coating–even though the system costs more.
As we outline below, the likelihood of reduced throughput due to downtime is consistently greater with conveyor systems, regardless of the volume of parts being processed.
4. Maintenance & Downtime
Maintenance is a critical consideration for any coating operation, and batch systems shine in this area. Because they have few moving parts and utilize relatively simple appliances, conventional batch systems are easier and less expensive to maintain than other systems. Routine cleaning and servicing can be performed quickly, minimizing downtime.
Conveyor systems, in contrast, are more complex and prone to mechanical issues. They must be cleaned and maintained more rigorously to avoid downtime from overspray build-up on trolleys or powder accumulation on the rail or track. A single malfunctioning trolley can shut down the entire line. Maintenance and repairs can be time-consuming and costly, leading to extended periods of downtime that can disrupt production schedules and impact profitability.
5. Scalability
Batch powder coating systems are inherently scalable. This is especially true with booths and ovens from Reliant Finishing Systems because their modular design allows the appliances to be made longer, taller, or wider without having to scrap the entire structure. As a business grows, the appliances can be enlarged or additional equipment can be added incrementally without requiring a complete overhaul of the existing system. This makes conventional batch systems an excellent choice for companies planning for long-term growth.
Conveyor systems, on the other hand, are less adaptable. Expanding a conveyor line often involves significant capital investment and infrastructure changes, which can be a major barrier for growing businesses. Another critical consideration is floor space. The footprint of the typical batch system is almost always smaller than that of a conveyor-based system with similar capabilities. In some cases, the difference can be staggering, with a conventional batch system taking up less than half the room. For many business owners, this is reason enough to abandon plans to use a conveyor to move their parts through the coating process.
Ready to Talk Batch?
For those seeking a coating solution that prioritizes affordability, versatility, and efficiency, conventional batch powder coating systems are the clear choice over manual push/pull conveyor-based coating systems. If you’d like to discuss your coating system requirements, the experts at Reliant Finishing Systems are ready to help! Give us a call at (256) 355-9000 and we’ll talk through your needs, provide a budgetary estimate, and promptly follow it up with a detailed plan that defines the equipment, layout, and costs associated with a new powder coating system.