Why you should trust in Gema parts only:
Gema prides itself on understanding your needs, and consistently delivering products and solutions that our customers depend on. Gema powder equipment is supported around the clock by local spares and support providers who operate an efficient supply chain and distribution centers across the globe. This means whatever part you need, we can get it to you quickly, minimizing your downtime.
Best coating performance:
- Genuine Gema parts are specially designed to work together to maximize component life and deliver first class coating performance.
- They ensure optimum coating performance, reduce powder consumption and increase energy efficiency.
- Gema parts restore best powder performance and transfer efficiency.
Full compliance with safety and health regulations:
- All Gema products supplied comply with current Health & Safety, DSEAR, ATEX, Electrical & Machinery directives and don’t compromise insurance validation.
- The usage of original components protects the safety and health of the operators and complies also with ecological standards.
Cost Savings and reliability:
- Gema components are designed to work together to maximize component life with consistent coating results and reliable performance.
- Gema parts match the individual product characteristics across the whole Gema equipment range, to fit first time and saving on costly downtime.
Full Warranty and support:
- Original parts are covered by Gema warranties worldwide.
- Full traceability of the Gema parts to the distribution network is ensured.
GEMA Product Features
OptiStar 4.0 – The benchmark for the efficient gun control
OptiStar 4.0 gun control ensures an optimized application with an exceptional coating result. The new generation of OptiStar presents the proven DVC- and PCC-Technologies and the new Electrostatic App, delivering an intelligent control to provide a seamless link to Smart Factory Automation.
Dynamic Contour Detection
- Coat difficult object shapes with ease
- High level automation of the application process
- Automated recognition of complex geometries
- Optimized coating quality
- Powder savings and reduction of over-spray
- Drastic reduction of the manual coating operation
- Automated programming of U-axes
Automation from Gema Switzerland GmbH
GEMA sets a new standard in powder coating with intelligent automation components that increase your productivity, minimize the coating complexity and give you full control and access to the application process. Achieve perfect coating results, even on the most complex part geometries, with state-of-the-art powder coating automation.
OptiStar 4.0 – Technical Animation
OptiStar 4.0 gun control ensures an optimized application with an exceptional coating result. The new generation of OptiStar presents the proven DVC- and PCC-Technologies and the new Electrostatic App, delivering an intelligent control to provide a seamless link to Smart Factory Automation.
Powder Coating Tips
| Cause | Remedies |
|---|---|
| When the powder coating on the object is too thick, an uneven surface is created. | If the coating thickness cannot be reduced, the use of a SuperCorona® ring will effectively prevent the formation of the “orange peel effect”. See also Back ionizer. |
| Cause | Remedies |
|---|---|
| The use of silicon in the coating area is often the cause of a bad coating finish. | Because all powders react “allergically” to silicon, it must never be used in the coating area. |
| Cause | Remedies |
|---|---|
| Workpieces grounded insufficiently. | Clean the hangers and hooks. |
| Powder resistance too low. | Contact your powder manufacturer. |
| Poor grain size distribution. | Contact your powder manufacturer. |
| Field strength too high. | Change the current, and gun to object distance. |
| Powder is blown out of the corners and cavities by too much air pressure. | Reduce the Total air pressure. |
| Too little penetration in the corners and cavities caused by too high current or using of the wrong nozzles. | Reduce the current and use more suitable nozzles. See also Nozzles. |
| Poor pre-treatment. | Contact the supplier. |
| Wrong oven settings (too high, too low, curing time too long). | Improve the oven settings. |
| Unsatisfactory powder quality. | Contact the Powder supplier. Change the powder. |
| A too rapid stroke movement can break up the powder cloud. | The stroke speed should not exceed 0.6 m/s - values between 0.2 - 0.4 m/s are recommended. |
| Cause | Remedies |
|---|---|
| Grain distribution too fine. | Contact the powder manufacturer. |
| Humidity in the powder due to incorrect storage. | The powder must be dry and stored at the working temperature. |
| Sintering in the nozzles caused by a too high Total air pressure. | Reduce the Total air pressure to 4 – 5 Nm3/h. |
| Poor fluidization in the powder container caused by humid compressed air or a clogged fluidizing plate. | Check the compressed air for cleanliness, replace the fluidizing plate. |
| Cause | Remedies |
|---|---|
| The so-called back ionization is created when the powder coating is too thick. | Reducing the high-voltage prevents back ionization; this however, results in a reduction of the powder transfer rate. Back ionization formation is also dependent on the temperature, and relative humidity. With very difficult powders air-conditioning of the coating area may be necessary. See also “Orange peel”. |
| Cause | Remedies |
|---|---|
| When powder suddenly escapes from a well set up booth, and the pressure monitoring of the exhaust system displays normal values, then the fault is usually to be found in the booth surroundings. | The most frequent cause is draughts from open doors or windows in the workshop (even far away from the booth). |
| Cause | Remedies |
|---|---|
| Unsatisfactory sieve machine. | When a smaller mesh is not sufficient, fitting a sieve machine with automatic contamination removal should be considered. |
| When the chain conveyer is not cleaned regularly or unsuitable grease/oil is used. | Clean regularly, and when necessary, fit a hood. |
| When powder is blown into the oven. | Check the workshop for air currents. |
| Powder residue in the oven. | This can be prevented by regular cleaning. |
| Poorly cleaned recovery system. | Clean regularly. |
| When dirty air is sucked into the booth or the oven. | Under certain conditions the coating plant must be separated from the production areas. |
| When a number of booths are operated together, it can happen that cleaning is influenced. | In this case the booths must be separated further away from each another. |
| Cause | Remedies |
|---|---|
| Fluidization of the powder has a great influence on the coating quality. | In addition, with difficult powders we recommend to add a vibration of the powder hopper. Retrofitting a pneumatic or electric vibrating table is simple. Remark: GEMA OPTICENTERS ARE NOT PREPARED TO WORK WITH A VIBRATING TABLE. |
| Lumps appear in the fluidized powder, if the powder is stored too long or came into contact with temperatures over 35° C (95° F). | Use new powder and check the storage conditions of the powder. |
| Poor fluidization of the powder can be caused by the fluidizing air being set too low. | Check the fluidizing air setting. |