Catalytic Heating is Fueling the
Future of Powder Coating Economics
Natural Gas Catalytic Ovens
Are an Essential Element in
Powder Coating’s Growth
Finishing operations that use solvent-based Paints are
increasingly switching to powder coating materials to
prevent air toxic emissions and help plants avoid
costly EPA Maximum Achievable control Technology
(MACT) compliance. Compliance with emissions
regulations is an important driver as evidenced by the
50% reduction in use of solvent-based coatings achieved
in the last 5 years; however it is not the only reason.
Powder coating technology has demonstrated
significant operating cost reductions, and improved
coating durability and appearance, and has provided
substantial production line performance improvements.
Gas fired catalytic infrared powder coating lines are
the preferred technology in many cases, spurred on by:
low operating costs; minimal thermal loss; precise
temperature control; complete drying penetration; and
minimal floor space requirements.
Catalytic Heating is Fueling the
Future of Powder Coating Economics
Natural Gas Catalytic Ovens
Are an Essential Element in
Powder Coating’s Growth
Western Pacific Storage Systems, a fabricator of industrial steel storage products
converted its coating line to electric infrared several years ago. The powder coating process
solved emissions problems, but the electric infrared oven was costly to operate and required long
curing cycles.
Working closely with the Southern California Gas Company, Western Pacific examined several
production options and determined its best solution was a production line change-over to natural
gas infrared technology.
Economics
Monthly production figures
at Western Pacific are
variable. To assess the true
savings, actual production costs
during four mouths from the
year before and the year after
the switch were compared. The
total output for each year from
the four months selected (May,
June, July, and August) was
comparable (2,349 storage units
before the switch and 2,363 after
the switch). As the figure shows,
total plant energy costs were
$78,417 from the four months
before the switch to catalytic
heating, and $54,739 from the
same four months after the
switch. This is an average
monthly savings for the entire
facility of $5,919 or an annual
savings of $71,018 which is
about 30%.
If changes in electric and gas
demand for the catalytic oven
only are considered, process
savings are dramatic. Before
conversion, the catalytic oven
required $37,570 in electricity to
produce 2,349 storage units.
After conversion, the oven
required only $13,893 in natural
gas to produce 2,363 storage
units (electricity required for
preheat is virtually zero). The
result of the conversion is thus
an eye-opening 63% reduction in
energy costs.
Western Pacific Storage Systems
Western Pacific Storage Systems fabricates industrial steel storage products.
At one point in the fabrication process, a powder coating is applied to the
product. The coating must be thoroughly cured before the next manufacturing
steps can take place. Until about a year ago, Western Pacific was using
electric infrared to cure the powder coatings. Although the technology did
its job, it was costly to operate and took too long to cure. Catalytic infrared
heaters, which have been around for more than 30 years, were the solution.
“The catalytic heaters give us more curing capacity, which is exactly what
we wanted,” explains Paul Bautista, Director of Manufacturing at Western
Pacific Storage Systems in Monrovia, California.”We get more heat out of
the system, and that makes our curing process much quicker.” That’s approximately
36% quicker, and almost $72,000 per year less expensive, according
to figures obtained by the Southern California Gas Company in a recent
comparison study.
Catalytic infrared is especially beneficial in drying and curing powder- and
water-based industrial coatings. Although powder coatings may require
longer cycle times and tend to be more difficult to cure than solvent-based
coatings, they are environmentally favorable and are becoming increasingly
popular.
Speeding Up and Reducing Overtime
Western Pacific also increased its line speed from 11 to 15 feet per minute
by switching to a catalytic oven that uses catalytic infrared heating. This
36% increase was obtained without even reaching full oven capacity, as
production is now limited by the speed of the washer and powder coater. The
increase in speed means production demands are met at a faster pace while
overtime is significantly reduced.
“We certainly like this furnace,” concludes Western Pacific’s Bautista.
“Overall, it’s been very good for us.”
Vulcan Catalytic Systems, Ltd. | PO Box 855, Portsmouth, RI 02871 | 401-683-2070
| Email: jmartin@vulcan-mdf.com
Finishing operations that use solvent-based Paints are
increasingly switching to powder coating materials to
prevent air toxic emissions and help plants avoid
costly EPA Maximum Achievable control Technology
(MACT) compliance. Compliance with emissions
regulations is an important driver as evidenced by the
50% reduction in use of solvent-based coatings achieved
in the last 5 years; however it is not the only reason.
Western Pacific Storage Systems, a fabricator of industrial steel storage products
converted its coating line to electric infrared several years ago. The powder coating process
solved emissions problems, but the electric infrared oven was costly to operate and required long
curing cycles.