Doughty Engineering Ltd. – Flexible Powder Coating System – Case Study

Doughty_Logo - cmyk

New Powder Coating System Improves Response Time

Doughty Engineering is the world leader in the design and manufacture of rigging, suspension and lifting equipment for the film, TV and theatre industry. Prior to installing a new powder coating system, the company outsourced all their powder coating to two subcontractors. Whilst they were generally happy with service that was offered; typical turnaround time was anything from 2 days to a week. However, it became  clear to Doughty Engineering that over the last 5 years,  customers were becoming more demanding. They were holding less stock and so expected suppliers to hold large stocks and offer short lead times. Maintaining large stocks was not the answer, especially when there are 100’s of products. However, the converse was not an option either. If a customer called for a part and it was not in stock, they would simply phone up another supplier. This created the risk of losing hard won business to competitors.

Doughty_parts

So the ability to become much more flexible and responsive became important. The answer was to bring 95% of their powder coating “in-house”. Working with systems house Junair (Spraybooths) Ltd,  Gema UK and Caldan conveyors, the optimum system was designed and implemented. For the oven, Heraeus Vulcan Gas Catalytic IR technology was chosen due to its superior energy efficiency, small footprint, and improved finish quality over conventional convection technology.


Powder Coating System


What Happened Next?

The system has now been running faultlessly since February 2014. Key improvements  are:

  • 10% operating cost saving
  • Increased throughput
  • Considerably reduced  lead times
  • Three hours not unusual
  • Rush jobs in custom colours carried out “While You Wait”
  • Improved quality
  • Increased capacity
  • Customer retention maintained
  • Production easier to manage

Stephen Wright a Director of Doughty Engineering Ltd. said:


“Apart from the reduction in operating costs and the improvement in quality; the intangible benefits such as improved customer service and the ability to be more responsive will help us maintain existing and gain new customers. The new powder coating system has surpassed our expectations and made an immediate difference to our business”


Energy Efficient Powder Coating System – Case Study

Working with our distributor in the Czech Republic, Surfin s.r.o, Heraeus Vulcan designed a new energy efficient powder coating system for Dikrt spol. s r.o. . The system is designed to cure powder on large agricultural parts, and the performance of the oven has exceeded expectation. Mr Weikert, the company’s owner stated:

“It used to take 70 minutes to cure our parts with the old convection oven. With the new Vulcan oven, it now takes only 12 minutes! We are very satisfied with its performance!”

energy efficient powder coating system

Large Parts Curing in Record Time in Energy Efficient Powder Coating System

Energy Efficient Powder Coating System

View of Energy Efficient Powder Coating System

How Did We Do It?

Working with our distributor in the Czech Republic, Jaroslav Blazek of Surfin s.r.o., the customer was able to see an existing Heraeus Vulcan system at another location and carry out part testing. Heraeus Vulcan then designed the powder coating oven to meet the customer’s requirements using SolidWorks. Heraeus Vulcan then provided Surfin s.r.o with a package that included the sheet metal design, the Heraeus Vulcan infrared heaters and the controls. To see a video on how Heraeus Vulcan designs and builds ovens, please follow the link.
The system was then easily constructed at the Surfin factory, with the sheet metal parts being produced locally from the SolidWorks files. The new energy efficient powder coating system was then installed and commissioned at the customer’s site within a few days.

Advantages of a Energy Efficient Powder Coating System from Heraeus Vulcan

All Heraeus Vulcan energy efficient powder coating systems operate using the principles of gas catalytic infrared heating. This type of system has an energy to effective heat conversion ratio of 85%, compared to traditional convection oven which is only 5% – 7% efficient. In practical operation this results in curing  taking a third less time in a gas catalytic infrared oven than a gas fired convection oven. This translates into significantly reduced energy bills.
The flameless nature of our systems means that there is no noxious emissions such as Nitric Oxide or Nitrogen Dioxide, so Heraeus Vulcan ovens are environmentally friendly.

If you would like more information on our energy efficient powder coating systems, then please contact John Martin (john.martin@heraeus.com) for USA enquiries or Ian Bartley (ian.bartley@heraeus.com) for UK and Europe.

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