Adding Value by Design

By Steve Owens

Founded in 1945 by Dick and Eleanor Dalsin in Bloomington, MN, Dalsin Industries’ roots lie in providing metal fabrication services as a job shop. Over the years, Dalsin has continually reinvented itself in response to market changes and customer demands.

In the late 1970s and early 1980s, Dalsin Industries pivoted from basic metalworking to more advanced precision metal fabrication. This shift was driven by the growing demand from OEMs for integrated solutions that included not just fabrication but also value-added services like welding, finishing, and assembly. The move positioned Dalsin as a comprehensive manufacturing partner rather than just a contract fabricator.

Investing in the Future
The early 2000s marked a significant milestone with the introduction of automated technologies. The company’s “automation adventure” began as a strategic response to evolving market demands and the need for greater efficiency, quality, and flexibility in manufacturing. In addition, machinery manufacturers invested heavily in automating their equipment and really brought the technology into the future. Over the years, Dalsin has integrated automation into nearly every aspect of our operations from laser cutting, bending, punching, and welding, to powder coating; it touches nearly every part of our process and has greatly improved production efficiency and precision.

The level and extent of automation in our shop is definitely a major investment. However, the bottom line is that automation done well increases capacity, efficiency, quality, cost-effectiveness, and scalability. While we do run “lights out” on our automated laser cutting and punching systems, it is important to keep in mind that automation is not a set it and forget it type of activity. It involves continuous investment in training for our employees to ensure they can operate and maintain this advanced equipment effectively. We remain dedicated to our automation adventure as the technological advancements it has provided enable the company to meet the high standards and tight tolerances required by our diverse clientele.

Powder Coating Prowess
Years before diving into automated powder coating, we began with a manual system, which included a mini wash bay and a small batch booth and oven. This initial setup about 12 years ago allowed us to learn the ropes and experiment. From there, we started working with Brian Garvey and Parker Ionics to set up a GX7000B box feed unit paired with a GX121 manual gun.

After extensive experimentation and investigation, we recognized the need for a more robust system to meet our customers’ growing demands. Dalsin purchased a larger booth from Parker Ionics and ran our first parts in June 2020. Initially, we used a manual spray booth with two painters, one on each side. However, we quickly realized that automation was the future, not only in sheet metal fabrication, but in powder coating as well.

In late 2022, Dalsin began offering medium to high volume on-site powder coating of aluminum, carbon steel, and stainless steel. We opened a new powder coating line featuring advanced technology like automated conveyors, a five-stage washer with nanotechnology conversion, and high-capacity dry-off and cure ovens. To ensure a high- quality finish, the process begins with an alkaline cleaner in the first stage, followed by two rinse stages. After rinsing, the parts move through a nano conversion tank for enhanced adhesion and corrosion resistance, and then a final clean water rinse before heading to the dry-off oven.

We expanded the booth by eight feet and added automated components, including eight automatic guns, four on each side. The automatic guns are powered by light curtains triggered to turn on the guns that are needed for the job, whether it be two or all eight. Along with the automatic guns, we use a single powder coater with a manual spray gun for touch-up.

The new line enhances the company’s finishing capabilities, ensuring high-quality and environmentally friendly coatings for a wide range of applications. These changes allowed us to double our line speed, as well as increase line density. There was also a substantial cost saving in going to the automatic guns. One less painter in the booth and a more consistent powder flow from the guns saved us on wasted powder, giving us much better transfer efficiency than our early days of spraying manually.

Looking ahead, we are considering adding a secondary booth or enhancing our current setup with a reclaim system instead of our current spray-to-waste method. Additionally, we’re exploring the idea of an environmental room around the powder coat booth to regulate temperature during the application process, which would also provide a controlled environment for powder storage.

Designed for Mutual Benefit
Always looking to provide added value, Dalsin offers design for manufacturing services (DFM) to all of our customers. Our decision to incorporate DFM was driven by the need to optimize production processes and reduce costs for both Dalsin and our clients. By collaborating closely with our customers during the design phase, we can identify potential manufacturing issues early and suggest modifications that would streamline production, improve product performance, and lower costs. This proactive approach not only enhances the quality and functionality of the final products but also significantly shortens lead times.

DFM services are highly valued by our customers, and a substantial portion of our projects involve these principles. Our clients range from small businesses to large OEMs across various industries, including energy, transportation, and appliances. They frequently take advantage of our design services to ensure their products are not only manufacturable but also optimized for performance and cost.

Harnessing the Sun
As a company deeply invested in the future of manufacturing, we recognize the importance of adopting green initiatives that not only benefit the environment but also enhance our operational efficiency. The decision to install a roof solar system was driven by a commitment to sustainability and reducing our environmental impact. It’s also a smart business decision as many of our customers are now looking for environmentally progressive partners.

Our solar installation is comprised of 3,096 panels which, if laid end to end, would stretch for more than 3.75 miles. The system generates approximately 41% of our energy requirements, translating to about 1,374,624 kilowatt-hours of clean energy annually. This substantial contribution from solar power helps to operate various aspects of our manufacturing processes, including our powder coating line. We’ve also partnered with a third party for another 0.8 megawatts of energy via a community solar garden which, combined with our solar roof system, accounts for 50% of our electrical energy needs. The integration of solar energy into our operations ensures that even energy intensive processes like powder coating are more sustainable and environmentally friendly.

Dalsin is also pursuing the Zero Waste certification through the U.S. Green Building Council. The certification process will help us become more resource efficient, minimize solid waste, and improve our production processes and sustainability strategies. Let’s face it, manufacturing is inherently energy intensive, but we can and are taking steps to minimize our environmental impact.

Recipe for Success
Over the years, Dalsin has continually reinvented itself investing in technology and innovation to meet evolving market needs while remaining true to the pillars on which it was built—respect, hard work, family values, and a good sense of humor.

Perhaps the fourth pillar, a good sense of humor, raises an eyebrow. Well, it’s hard to be successful for nearly 80 years without it! We’ve found that a good laugh can dissolve stress, spark creativity, and make Monday mornings pleasant. So, while we’re serious about precision and quality, we’re also serious about not taking ourselves too seriously. It’s this blend of professionalism and playfulness that makes Dalsin a great place to work and do business with— after all, happy employees make the best metal fabricators and powder coaters!

Steve Owens is director of new business development at Dalsin Industries.