Taking a hard look at critical manufacturing processes can be time consuming, labor intensive and ultimately lead to disruptive, yet productive change. Often times,
short-term solutions are applied to reduce the downtime and
frustration associated with process overhauls.
But for Beacon Products, a division of Hubbell Lighting, a
move into a new 150,000 square foot facility made a review
and finishing line overhaul worthwhile. A ‘one-stop’ resource
for architects, landscape architects, engineers and lighting
designers, the Bradenton, Florida, company manufactures
marine-grade, copper-free cast and extruded aluminum architectural outdoor lighting and associated products for commercial and governmental projects worldwide.
Prior to the move, Beacon’s finishing process was in a state
of flux. Liquid coatings were still being used for some products, and powder finishing pretreatment utilized a chromate
(caustic) system. Powder coating finish quality was a concern
as warranties are critical for Beacon’s customers. When designing the new facility, the company conducted a vigorous audit
of its finishing process – they knew there were improvements
and efficiencies to be found.
New thinking + new partners = new
results
As part of its relocation, Beacon initiated a partnership
with Sherwin-Williams that converted all finishing to powder coatings, helped change the finishing operation’s pretreatment procedures, and improved the existing powder
coating process.
“We were working with an outside consultant to see how
we could improve overall results while still using our existing
coating suppliers,” said Perry Romano, vice president, Product
Development. “Unfortunately, we were getting poor results for
salt spray tests. We called in Sherwin-Williams, and they helped
us a lot, beginning with the pretreatment process. They helped
us tweak the process so that it was perfect.”
Beacon’s existing powder coating pretreatment proce-
dure used a sandblasting and chromate process to improve
coating adherence. While effective, the process was also
expensive, and required removing the residue for off-site
treatment as hazardous waste. Beacon sought a more sus-
tainable solution. The answer was a five-step, chromate-free
dipping process in which parts – some 20 to 25 feet long –
are moved via overhead crane along a line of 40’ immersion
tanks and dried before entering the powder coating booths
and ovens.
“With the new pretreatment system, we don’t need to
have the residual liquid hauled away,” Romano said. “All of
the excess water goes into a large cylinder, where sediment
settles to the bottom. We have a permit that allows us to put
the leftover water directly into the sewer system. I would
estimate that in the first year, this saved us approximately
$50,000, and we’ve grown since then. I’d have to say it’s
probably a savings of several hundred thousand dollars an-
nually today.”
As a partner to Beacon Products, Sherwin-Williams provid-
ed training to improve powder coating techniques. The finish-
ing line’s powder coating transfer efficiency was increased, and
film build was made more consistent through the training pro-
cess and enhancements to the line’s procedures. The primary
coatings used are Sherwin-Williams Powdura 4000 and 5000,
which are color matched to products in the Beacon catalog
for next day delivery from Sherwin-Williams’ Tampa facility.
Custom colors that include mirror finishes and certain pati-
nas of green to simulate an aged copper look are matched to
Beacon’s specifications.
Sherwin-Williams also developed a textured finish.“We
wanted a certain type of texture to the finish,” Romano said.
“When you’re dealing with castings, you want to be able to
cover up some of the imperfections. The textured finish really
helped us.”
Certification provides competitive edge
The finishing line upgrades have paid off. Confidence in
the quality of its finishing process allowed Beacon Products
to achieve AAMA 2604 and AAMA 2605 certification for
its Beacote-V and Beacote-X paint finishes, warranting
the finishes for five and ten years, respectively, based on
Finishing Line Upgrades Deliver Certifiable Improvements For Metal Architectural
Products Manufacturer
Sherwin-Williams Product Finishes
BEACon PRoDUCTs CAsE sTUDy
