PCI’s 2012 Custom Coater Summit was a huge
success at the Treasure Island Resort in Las
Vegas. The event was held on March 22-23
where approximately 40 coaters attended. The agenda
included topics on business solutions, marketing
in today’s economy,
leadership and
motivation, managing
your employees,
and product
innovations. There
were several outstanding
speakers,
including David
Chalk, Galaxy
Associates; Eric
Koslow, Decoral;
Sam Miles, Miles
Chemical Solutions;
Steve Houston, TCI
Powder; Scott
Landgraf, In-Line
Sieve; and Rodger
Talbert, PCI. The
keynote speaker,
Barry Maher from
Barry Maher &
Associates, had abundant reviews as he presented on
self- and employee motivation in his “Filling the Glass:
Real World Tactics and Reality-Based Motivation for
Increasing Productivity and Job Satisfaction.” Not only
did he give useful and inspiration points, he did so with
high energy and humor. Custom coaters also had the
opportunity to participate in a variety of round table
discussions, which are open discussions in order to help
each other resolve challenges and go home with new
ideas and solutions.
Overall, the attendees had a great time and went
home with many valuable
resources they
can apply in their
businesses. Based on
feedback, many were
surprised by the
extent of content they
learned in the two
days and will definitely
be back next year.
Attendee Heather
Koehler, Advanced
Powder Coating
& Sandblasting,
writes, “I would
like to thank you
and everyone at
PCI for such an
amazing event.
We were blown
away with all the
knowledge of the
powder coating business in one room. We will definitely
be attending next year’s event!”
The Custom Coater Summit is held in March every
year in Las Vegas. Check out www.powdercoating.org
for details about 2013’s event, which will be posted as
they become available.
Chemetall Opens Plant in Chennai, India
Chemetall-Rai, a member of the Chemetall Surface
Treatment Group, has invested in a second production
facility in India. The design and construction of
this new plant set new benchmarks in safety and quality,
while responding to the increasing demand for local sourcing
in this growing region. The new facility will enhance
Chemetall-Rai’s current capacity substantially. “To keep
“The investment in our new plant is a further milestone
in Chemetall’s expansion strategy and it clearly demonstrates
the importance of the Indian market,” stresses Joris
Merckx, president, Chemetall Surface Treatment. Recently
the company has acquired the chemical business of
Gramos, one of the major local players of surface treatment
technology for the Indian automotive industry.
Chennai, also known as the “Detroit of India,” has a
significant importance for automotive OEMs and component
manufacturers. The automotive industry is of particular
interest for Chemetall, as it triggers innovation, sets
high quality standards and feeds many other metal-producing
industries. With a modern production plant close to the
Hyundai, Ford and Renaullt Nissan manufacturing facilities,
Chemetall is following its strategy to provide state-ofthe-
art quality technologies as well as local support for
global customers.
In other Chemetall news, the company has announced
that the Mercedes-Benz plant in Gaggenau changed its
pretreatment from zinc phosphating to Chemetall’s more
eco-friendly Oxsilan technology. In the new pressing plant
of the Mercedes-Benz site in Gaggenau, which is one of
the oldest car factories in the world, each day more than
1,400 spare parts like doors, trunk lids, fenders or engine
hoods for all Mercedes-Benz models are manufactured,
pretreated and painted. Formerly, the components were
mainly made from galvanized steel. But aluminum is
increasingly making its way into automobiles. For zinc
phosphating, this increase in material mixes makes it
necessary to carefully explore the technical limits.
Adapting baths to the changing loads is complex and the
disposal of heavy
metals expensive.
“The trend to
light-weight construction
will
increase further
in future.
Mercedes-Benz
therefore needed
an alternative
that was free
from heavy metals
and compatible
with multimetals,”
explains
Klaus Rudo,
responsible for Global Process Release at Daimler.
After several months of testing, the new technology
was adopted for use in series production in spring 2011.
For Sascha Malorny, responsible for pretreatment and
painting at Mercedes-Benz in Gaggenau, “It used to be
that the phosphating zone had to be acid-rinsed every 10
weeks, which took a whole weekend each time. With
Oxsilan, cleaning of the complete facility is completed
after only six to eight hours.” Previously, the filter system
had to be cleaned once a week, which meant a complete
exchange of the filter mats. Today, it is sufficient to rinse
the filter press once a month with water since the
new pretreatment technology is virtually sludge-free.
Graco Closes Finishing Brands Acquisition
Graco announced April 2 that it
has closed on its $650 million
acquisition of the Illinois Tool
Works’ finishing businesses, reaching
an agreement with the U.S. Federal
Trade Commission that allows for closing
of the powder finishing business
while the FTC investigates and considers
a settlement proposal from
Graco for the liquid finishing side of
Gema’s business.
A week earlier, the FTC issued an
order for Graco to hold the liquid finishing
assets separate from the powder
finishing and other Graco businesses
while the FTC investigates
and considers a settlement proposal
from Graco. Although the liquid businesses
are now owned by Graco, they
will be run independently by existing
management under the supervision
of a trustee who reports directly to
the FTC.
At the completion of its review, the
FTC will issue a
final decision
and order that
will identify the
products, businesses
or assets
that Graco will
be required to
divest. The
divestiture must be completed in the
180 days following the issuance of
the final decision and order and may
include up to all of the liquid finishing
businesses.
The acquisition includes complementary
powder and liquid finishing
equipment operations, technologies
and brands. In powder finishing,
Graco has added Gema, and approximately
one-third of the purchase price
is expected to be allocated to this business.
In industrial liquid finishing, the
acquisition includes Binks spray finishing
equipment, DeVilbiss spray
guns and accessories, Ransburg electrostatic
equipment and accessories
and BGK curing technology.
“The addition of the Gema Powder
Finishing business to Graco’s existing
finishing operations is highly strategic
and complementary,” says Patrick
McHale, Graco’s president and CEO.
“It allows the Company access to
attractive end markets; the global distribution
base of Gema is strong and
growing; the emerging market exposure
is highly attractive; and the
brand name is well established with
end users as a high quality, technological
leader.”
“This is going to be an extraordinarily
exciting time for all of us as we
work to make our successful business
even better,” says Claudio Merengo,
Gema Group president. “This change
in our corporate ownership will
enhance our ability to provide high
quality products and continued excellent
service.”
In the next several months, a
transition will occur as marketing,
promotional and product materials
are integrated with the new company
name, Gema.
Peerless Plant Tour, CCAI
As reported in the Fall 2009 edition of this magazine,
Peerless Industries Inc., Aurora, Ill., a designer,
manufacturer and distributor of audio-visual solutions,
moved its outsourced manufacturing back to the
United States. (Visit our digital edition for the full story
at www.nxtbook.com/nxtbooks/pct/fall09).
This has been successful for Peerless-AV. The company’s
made-in-the-USA product line includes flat panel
mounts, projector
mounts, wireless
technology, motorized
mount solutions,
audio cables, video cables, interactive kiosks, AV
furniture, AV racks, AV shelves, precision gear products,
surge protection, screen cleaning products and a full
assortment of accessories.
A 70-year-old global company, Peerless-AV has
remained at the forefront of the industry, creating new
AV technologies that push the envelope and provide ideal
solutions to meet the needs of the consumer and pro
markets, alike. Peerless-AV manufactures over 3,600
products that serve original equipment manufacturers,
commercial integrators and consumer retailers in 28 vertical
markets worldwide through direct sales representatives
and authorized distribution.
Thanks to a plant tour organized by The Chemical
Coaters Association International, Northern Illinois
Chapter, this past March 20, attendees were able to
experience Peerless-AV’s success up close and personal.
CCAI members and non-members alike were welcome to
attend the event, which consisted of a company overview
followed by a plant operations tour, including manufacturing
and finishing, and brief CCAI-NI presentation
and a catered dinner.
DuBois Aquires Galaxy
Associates
DuBois Chemicals, a specialty chemicals manufacturer
based in Sharonville, Ohio, has acquired
Galaxy Associates, another Cincinnati-based
provider of specialty chemicals solutions. The companies
are not just geographically close; they share similar products
and serve many of the same end markets. DuBois
Chemicals manufactures and markets synthetic compressor,
synthetic chain and other oils and greases as
well as its Lubricoolant and
Double-Cut brand of cutting
fluids and Polydraw brand of
pressworking fluids.
Founded in 2002, Galaxy
provides specialty chemicals such as metalworking fluids,
process chemistries, conversion coatings, sealing
rinses, and cleaners. The company has built its reputation
through its Industrial, Pulp & Paper, and
Transportation divisions, each of which provides products
to a specific customer set. Galaxy has expanded its metalworking
business by acquiring several metalworking
fluid companies during the past several years. In 2004,
Galaxy acquired Fremont Industrial expanding its Metal
Finishing business. In 2007, Galaxy purchased
Innovative Chemical Solutions (ICS), a metalworking
based company. In 2009, Challenge Inc. was purchased
by Galaxy expanding sales and product offerings in
metal finishing and mask washing operations.
“Galaxy bolsters DuBois’ industrial metal finishing
business while adding complementary capabilities to
DuBois’ transportation and paper segments,” says
Riverside Partner Tim Gosline. “We expect customers of
both firms to benefit from enhanced capabilities and a
broader suite of products.”
Galaxy is the fourth add-on that
Riverside has completed for DuBois
Chemicals since it acquired DuBois in
2008. Prior add-ons include Blendco,
Perkins Products and Mitco.
“Galaxy is a truly great entrepreneurial
company,” says DuBois CEO
Jeff Welsh. “The complementary
nature of our cultures, products and
end markets will allow us to deliver a
breadth of solutions that exceed our
customers’ expectations. It’s a really
natural fit for our marketplace.
Together we offer thousands of innovative
specialty chemical solutions that
we can deliver with creative passion
and expertise.”
Visit www.duboischemicals.com
PCI Certification
PCI has developed the PCI 3000
Certification Program, which is
available to all custom coaters
applying powder coatings, to acknowledge
coaters who can meet a standard
of product quality that fits their market
and meets or exceeds all of their
market needs and advertised standards.
In addition, PCI offers the PCI
4000 Certification Program, which is
designed and offered to all original
equipment manufacturers (OEMs)
applying powder coatings. This is the
certification that DSI has earned.
The audit process exposes the powder
coater to a thorough examination
of their equipment and process used
for application. It also examines their
business operation from raw materials
to finished products. This includes the
safety culture within the company,
inventory control, quality control,
process control, and customer satisfaction.
The entire operation is examined
to make sure that the powder coater
can deliver their expressed level of
quality on a regular basis. In addition
to the initial audit, the coater is
required to perform routine internal
audits and they are required to schedule
an annual audit by PCI to reaffirm
their continued compliance with the
goals of the program.
During the auditing process PCI
closely examine each of 12 operating
elements. These elements include:
1. Pretreatment of the substrate
2. Ovens used for drying and curing
3. Application of the powder coating
4. Incoming material quality control
5. Training practices and
competencies
6. Maintenance of the system
7. Customer satisfaction
8. Safety record and practices
within the operation
9. Process control
10. Warranties, guarantees and
performance expectations
11. Final quality control practices
12. Loading, unloading and
packaging
Within each element, the powder
coater must meet a minimum required
score in order to receive the approval
of PCI and become certified.
As of press time, the following companies
are PCI Certified.