Metal Powder Coating - Percival Scientific

VULCAN CATALYTIC INFRARED OVENS AT PERCIVAL SCIENTIFIC

Summary: Percival Scientific replaced conventional drying ovens used for paint curing with a Vulcan natural gas catalytic infrared oven. In addition to lowering natural gas usage and costs, the new system allowed Percival to implement a powder-based painting system which improves product quality and increased production. Percival received a $30,000 rebate from MidAmerican's Custom Systems program and now saves over $25,000 per year on its MidAmerican gas bills.

Customer Background: Percival Scientific, Inc., located in Perry, Iowa, manufactures climate-controlled research chambers for the biotech and university research industries. The research chambers are custom built to buyers' specifications in an array of sizes, rack and shelf options, and climate-control needs. Manufacturing tolerances are critical and quality is paramount.

Sheet metal fabrication is a large part of the manufacturing process. Prior to installing the Vulcan catalytic IR ovens, Percival used a liquid paint process that consumed significant amounts of natural gas for curing ovens as well as for reheating make-up air. In addition to its high gas usage, the old process had disappointing curing quality and required refinishing almost 70 percent of the time. Percival investigated a process upgrade to the new powder-based system, but soon found that the old ovens would not meet the necessary curing requirements.

How the Program Works: Percival replaced 17 feet of conventional infrared oven and 62 feet of convection oven with a 30 foot Vulcan natural gas catalytic infrared oven. Percival also removed the make-up air unit required for the liquid paint booth. The infrared oven is aVulcan Catalytic Systems unit sold by JN Industrial Solutions, LLC of St. Paul, MN.

Percival worked with JN Industrial Solutions and Can-Am Finishing Systems to install the new equipment. Initially, the company had concerns regarding product quality with the powder-based process, especially on pieces with complex geometry. However, component testing at the equipment manufacturer, Vulcan Catalytic, provided very positive results and Percival committed to purchasing the new system.

JN Industrial Solutions worked with the MidAmerican product manager to get the project approved through the Custom Systems program. Based on the information provided on project costs and energy savings, MidAmerican evaluated project cost-effectiveness from Percival's perspective as well as a broader, societal perspective. Since the project passed the societal cost-effectiveness test, MidAmerican was able to provide a rebate that represented two years of energy savings.

The project lasted nine months from inception to production. MidAmerican authorized the rebate payment within seven days of receiving Percival's completion/verification form and delivered the rebate check ~upon verification that the unit had been installed as specified.

Benefits: Percival now saves over $25,000 per year in natural gas costs, based on annual gas savings of 34,000 therms per year. The gas savings include 19,000 therms per year for the curing ovens and another 15,000 therms per year for the elimination of the make-up air unit. Installation costs for the catalytic oven totaled $100,000, with $30,000 paid by MidAmerican's rebate and the remaining $70,000 paid by Percival. Based on gas savings alone, the project provided Percival Scientific with a 2.8 year simple payback on its investment.

The new oven also allowed Percival to implement the new powder-based drying process. Reworking of parts, which was required almost 70 percent of the time with the old system, is now a rarity and overall production has increased significantly. In addition, the powder-coat paint process produces a brighter, whiter finish to the research chambers.

The catalytic infrared oven has performed better than Percival or JN Industrial Solutions expected before the installation. Flat pieces require even less gas than originally projected. In addition, due to the extremely fast response time of the catalytic infrared, Percival now turns the unit down to idle during lunch and breaks to create additional energy savings.

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