Innovativetechnology Legendaryreliability George Koch Sons

Innovative technology
Legendary reliability
George Koch Sons
®
SURFACE FINISHING: ELECTROCOATING
Koch e-coat systems are used in more
We design our e-coat systems to fit
We use proven component
than 200 facilities around the world,
into the smallest footprint possible.
systems to minimize maintenance
by some of the most demanding
They can be installed and moved
and maximize uptime. We offer
customers in the world. We specialize
quickly and conveniently. They are
systems with fiber optic-sensing units
in turnkey systems, including surface
designed to accommodate ovens
and user-friendly PLCs. Our systems
preparation, e-coating, and curing, as
on top or to the side, depending on
are designed to pay for themselves
well as material handling, wastewater
available headroom. They are also
quickly, with low initial costs, the
treatment, chemical recovery,
designed to integrate easily into a
lowest operating costs, and the
controls, and auxiliary systems.
variety of new or existing material
highest quality and reliability in
handling systems.
the industry.
SURFACE FINISHING: ELECTROCOATING
For more than 40 years, we’ve worked with customers around the world to
design, upgrade, or replace their e-coat systems. In fact, we designed and
installed the first industrial e-coat system in North America. We are experts in the
technologies involved—pretreatment, application, curing, wastewater treatment, chemical recovery, and control-and we are experts in bringing them
together to meet your needs. We are founding members of The Electrocoat
Association and proud of our three recipients of the prestigious Brewer Award for
excellence and innovation in electrocoating technology
Our single- and dual-tunnel FRP
Our material handling systems
and metal pretreatment systems
are designed by a dedicated
engineering group and include
provide spray and immersion
degreasing and metal conditioning.
They can be designed to accommodate oversized parts, fit into
limited floor space, and be
operated in-line or manually.
Our FRP systems are highly-resistant
to chemical and mechanical
damage, compatible with all
solutions used for metal treatment,
and easy to install and maintain.
We design ovens to preheat, cure,
and dry to exacting material, production, and quality requirements.
Our ovens include high-velocity
convection, IR, high-velocity/IR, and
black wall radiant systems, with
overhead, side, or floor-mounted
ductwork, along with air filtration,
heat recovery and exchange, and
control systems. All are designed to
provide uniform part temperatures
and consistent temperature curves.
monorail, power & free, walking
beam, programmable hoist,
DeBurgh™, Pacer™, chain-onedge, AGV, flatline, and other
conventional conveyor systems.
The indexed programmable hoist
system pictured here features the
flexibility of multiple cranes in a
very compact overall layout.
SURFACE FINISHING: POWDER COATING
..
Powder is the fastest growing
Our bottom entry/exit curing ovens
segment of the coatings industry
create their own, natural heat seal,
and, with our customers, we have
made significant contributions to
that growth. As in e-coating, we
specialize in turnkey powder systems,
including surface preparation,
application, curing, material
handling, wastewater treatment,
chemical recovery, controls, and
auxiliary systems. This system features
our technologically advanced FRP
washer and a clean room for
powder booths.
This dry-off/cool-down oven features
our exclusive, ceiling-mounted PFOs,
along with a sanitary conveyor guard
to reduce the risk of contaminants
being deposited onto parts. Ceiling mounted PFOs accelerate drying
or curing. They create very high air
turnover rates and ensure uniform
part temperatures at low cost.
which reduces operating costs and
eliminates the need for an air seal
that can be difficult to control. Air
seals also create air movement
over uncured parts, which is highly
inefficient in powder coating. The
oven pictured here also features a
sanitary conveyor guard to reduce
the risk of contaminants being
cured into parts.
SURFACE FINISHING: POWDER COATING
We’ve worked with customers around the world on powder systems for
nearly as long as on e-coat systems. We are Category A members of the
Powder Coating Institute, and we have long served as world leaders in
advancing powder coating technologies and expanding their use. We can
help you get the best powder or powder system for your money. In the process,
we can help you streamline your finishing, forming, and assembly operations,
reduce your operating costs, and improve the quality of your products.
Our KochSmart® Control
Systems provide precise control of
e-coat, liquid, powder, and flatline
finishing systems. They feature userfriendly, color touch-screen terminals
Koch gas and electric IR ovens are
with PLCs to automate, monitor, and
designed for rapid, uniform curing,
control finishing and auxiliary
and they are often used in systems
processes. They can handle
handling multiple colors that can
Powder coating finishes are durable
everything from simple systems to
cross-contaminate. They feature
and long-lasting, resist chipping and
the most sophisticated, and they
instant on/off to conserve energy,
scratching, and can be used to
can dramatically improve process
clean operation, small size, and very
produce a wide range of surfaces,
control, system reliability and
fast temperature ramp up. Fast ramp
from smooth to wrinkled to textured.
functionality, and safety.
up raises the surface temperature of
Overspray can be retrieved,
parts being cured to polymerize, or
eliminating waste. Because far fewer
gel the coating quickly.
VOCs are released, pollution control
equipment can be eliminated in
many instances.
SURFACE FINISHING: LIQUID
liquid finishing systems
Liquid spray coatings are the oldest
and most commonly used technologies in the finishing industry today.
Koch specializes in turnkey liquid finishing systems that include surface
Low solids and high solids, solvent-
preparation, high-efficiency down-
We have continuously advanced and
based coatings are widely used for
draft water wash and side/down draft
refined liquid coating technology to
finishing products made from metal,
paint spray booths, patented recircu-
enhance finish perfomance, address
plastics and wood. Environmentally
lating air make-up and abatement
environmental issues, and meet the
friendly, waterborne coatings have
systems, spray booth retention pits,
needs of our customers for greatest
rapidly gained acceptance in the fin-
and drying and curing ovens. Our
uptime performance and low
ishing industry, as well as UV curable
high-efficiency down-draft water wash
life-cycle costs. Our patented recircu-
coatings in niche industries.
and side/down-draft paint spray
lating air systems minimize exhaust air
booths provide clean, quiet working
volume and monitor the air stream to
High performance pigmented and
environments. Koch’s automotive-
ensure safe operating conditions. Our
clear liquid coatings are extensively
approved boots capture 99.9% of all
systems are used as stand alone com-
used on metal and plastic compo-
particulates, and can be installed at
ponents or in combination with e-coat
nents in the automotive and motorcy-
floor level. Side-draft paint spray
to meet stringent quality, cost, operat-
cle industries, which require smooth,
booths can be totally enclosed with
ing and emission requirements.
mirror-like finishes.
the addition of a supply plenum.
FLATLINE FINISHING: COATING SYSTEMS
Our curtain coating systems are
Our single and multi-zone high
compatible with most liquid coatings,
velocity convection dryers are used
We provide standard and customized
including hot-melt adhesives and
in many industries. They are well suited
flatline finishing systems for drying,
waxes. They are used in virtually every
for drying solvents and waterborne
application of paints, stains, sealers,
major industry, from wood-related
coatings on wood, glass, plastic,
topcoats, adhesives, and UV-curable
industries to corrugated, automotive,
metal and other substrates.
coatings, along with material handling
glass and electronics. They provide
Multi-zone dryers are available with
systems. We work with customers to
high film uniformity, and they eliminate
infared heat to increase drying
design coating systems, which are
washboarding and memory effects
versatility, and are available for
ideal for application of solvent or
that can occur with contact-type
all fuel sources, including natural gas,
waterborne coatings, adhesives, and
coaters. Only the liquid coating
propane, fuel oil, high and low
UV-curable coatings onto flat or near-
contacts the surface of the
pressure steam and electricity.
ly flat substrates. Koch pressure head
substrate.
curtain coating systems are available
Multi-zone dryers use progressively
higher temperatures and
in coating widths ranging from 12”-
Our hot wax curtain coating is
impingement velocities in each zone,
144” . Once coating thickness is
used in the corrugated industry to
to pace the drying action and ensure
determined, operation is virtually
deliver dependable, high-speed
total solvent or water removal before
automatic. Material transfer is
performance while maintaining a
the coating cures. The result is an
effectively 100%.
controlled film deposit on
extremely durable, defect-free finish.
processing sheets.
SPECIALTY PRODUCTS: HEAT PROCESSING
Koch ovens are built for years of
Oven air flows are designed to
reliable performance. They feature
meet specific process needs. A plug
18-gauge aluminized steel walls, with
at least 4" of insulation. Loading doors
have heavy-duty hinges and, like roof
panels, are corrosion-resistant and
non-absorbent. Ovens are available
for use with various fuel sources,
including gas, oil, electric, and steam.
They are wired and tested before
shipping, and they are covered by a
2-year warranty on our work, along
with warranties offered by
our vendors.
Our ovens reach temperatures up
fan recirculates air at a rapid rate
to 750°F and meet all guidelines
for greater temperature uniformity.
established by the National Fire
Adjustable louvers balance the air
Protection Association Standard 86,
flow for even heat distribution.
Factory Mutual, and OSHA. They
Control panels can be wall-mounted
feature high-temperature limit and
or remotely located and contain
air-flow switches, belt and drive
all electrical safety and control
guards, pressure-release door latches,
equipment. The oven shown here
and optional powered exhausts with
is custom-designed and steam
purge timers. The oven shown here is
heated, for use in heavy industrial
a clean-room model that provides
applications.
tight enough control for electronics.
SPECIALTY PRODUCTS: THERMAL & ACOUSTICAL ISOLATION SYSTEMS
We are industry leaders in the development of innovative approaches to thermal processing for curing, baking, drying, preheating, degassing, dehydrating,
aging, sterilizing, annealing, and more. These innovative approaches include IR
and UV curing and drying, along with high-velocity convection, high-velocity/IR,
and convection batch drying. We are also industry leaders in the design and
manufacture of thermal and acoustical enclosures and barriers, personnel
rooms, in-plant offices, clean rooms, and other isolation applications.
Our acoustical enclosure products
In addition to modular, expandable
are used for noise abatement, test
labs near production lines, and
control rooms for personnel. They are
constructed of roll-formed, tongue-ingroove panels with self-interlocking
vertical edges; high-density,
non-combustible, non-settling,
mildew-resistant acoustical fill rated
at NRC 1.00; with double-glazed,
tempered glass windows; acoustical
doors; and heavy-duty hardware. We
also design conveyor tunnels,
ventilation systems, and electrical
packages for power, lighting, and
communications.
Koch standard and custom-designed
thermal and acoustical panel
enclosures are designed for special
applications, such as isolation of
harmful ordisruptive noises. Specifications for custom-designed enclosures
vary, but might include STC 55 rather
than STC 42 acoustical panels,
triple- rather than double-glazed
windows, acoustical floors, recessed
electrical receptacles, ductless split
air conditioning, and a wide range
of energy-wise choices for lighting
and ventilation.
thermal and acoustical enclosures,
we design, build, and install clean
rooms for a variety of applications.
All of our enclosures offer the
highest structural integrity and
surface finish. They are available
knocked-down, pre-assembled, or
erected on site, and they are
available with removable panels,
windows, HVAC, electrical
accessories, lifting lugs, raised
computer flooring, outdoor
weathering packages, and more.
MATERIAL HANDLING SYSTEMS
Experience in material handling
We design, install, and provide
systems is critical to the successful
comprehensive after-sale support for
design and performance of every
e-coat, powder, liquid, and flatline
finishing system. Efficient movement
of products through various finishing
stages often demands the flexibility
to change cycle times in each stage,
to monitor and make adjustments as
the production line is running, and to
automate and carefully control both
movement through and transfer from
stage to stage.
Systems are designed by a dedicated
engineering group with experience
on hundreds of production lines, with
hundreds of customers, each of
whom has exacting specifications for
space, speed, automation, efficiency,
flexibility, reliability, quality control, and
system control. We understand the
material handling problems inherent
in each stage of various finishing
processes. We’ve faced them or
similar problems before, and we’ve
solved them.
material handling systems around the
world, including monorail, power &
free, walking beam, programmable
hoist, DeBurgh™, Pacer™, chain-onedge, AGV, and conventional flatline
systems. We are experts in finishing
processes. We are experts in material
handling systems, and we are experts
in integrating them into new or
existing production lines.
WASTEWATER TREATMENT & CHEMICAL RECOVERY SYSTEMS
O ur material handling systems are designed by a dedicated engineering group
and include monorail, power & free, walking beam, programmable hoist,
DeBurgh™, Pacer™, chain-on-edge, AGV, and conventional flatline systems. Our
modular environmental systems, including zero-discharge systems, are also
designed by a dedicated engineering group and combine wastewater treatment and chemical recovery for compliance with environmental regulations
and the highest cost efficiency.
We design modular batch,
Environmental regulations affect
duplex batch, and continuous
the most basic decisions about
treatment systems, including
pretreatment and paint finishing
processes. Our experience in these
processes has led naturally to our
experience in wastewater treatment
and chemical recovery systems. Our
comprehensive environmental
systems combine the two to ensure
compliance with regulations and to
ensure the highest cost-efficiency in
paint, powder, and other finishing
operations.
Our systems, including zero-discharge
systems, are designed by a
dedicated engineering group with
experience in the design, installation,
testing, training, and documentation
of hundreds of successful systems.
Engineers in this group work closely
with engineers in others, to ensure
that they understand every facet of
every system, and to ensure that
every system performs to specifications -from start-up throughout its
service life.
collection tanks, treatment
modules, clarifiers, sludge
thickeners, final pH adjustments,
sand filters, flow monitoring, water
re-use, and sand filter transfer.
Each system must integrate
effectively with the processes
that feed it, so it makes sense to
work with a single source, with
experience in both environmental
and paint and powder systems.
PROJECT MANAGEMENT
The most important decision in
If you need a turnkey paint,
planning new or expanded paint
We use the most up-to-date
powder, or flatline finishing system,
finishing and processing capabilities
engineering systems available for
or individual system components,
is deciding who you’re going to work
everything from system layout to the
we can help you bring your project
with. We know the technologies
design of individual components
in on time and on budget. We have
involved and the alternatives, and
and controls. We use the latest
a history of working well with our
we can serve as a single source for
manufacturing systems, to ensure
customers’ project teams. We have
all systems, as well as for after-sale
that components and controls are
a record of 98% on-time start-ups
support, after-market parts, and spare
manufactured or fabricated to
and 98% uptime. Finally, we get
parts. We have more than 70 people
specifications. We also use the
repeat business from some of the
with design and application
newest communications systems to
most demanding customers in the
engineering responsibilities, which
ensure effective communication with
world.
gives us a wealth of experience
our customers, including remote
from which to draw.
access to their systems for
troubleshooting.
CONTINUOUS BELT
ELECTROCOAT
for your small parts bulk coating solution
The Problem
The Solution
Hanging and removing small parts on racks is a
labor-intensive, expensive process.
KOCH-PPG CONTINUOUS BELT
ELECTROCOAT system automates the process to
substantially reduce total coating cost.
CONTINUOUS BELT ELECTROCOAT TECHNOLOGY
• Unique conveyor belt surface minimizes touch marks and allows dense belt loading.
• Continuous conveyor through coating, post-rinse, cure and cool down eliminates need for parts
transfer and minimizes marring.
• Conveyor belt continuously cleaned in line ensures effective ground.
• Flexible agitation system eliminates gas bubbles for superior finish.
• A special paint formulation enables coating densely packed parts without significant sticking or
excessive touch-marks.
Best Applications
•
•
•
•
Some touch marks are acceptable
Parts with curves, breaks, and angles
Parts that can be vibratory fed
Large part volume
Poor Applications
• Class A Parts (no touch marks acceptable)
• Parts that nest
• Very small volume
George Koch Sons, LLC
www.kochllc.com
10 South Eleventh Avenue
Evansville, IN 47744 USA
Phone: 812-465-9600
Fax: 812-465-9676
DELUGE WASHER SYSTEM
for your small parts bulk coating solution
KOCH PRETREATMENT DELUGE revolutionary patent-pending design
• Meets unique challenges of small parts bulk coating
• Meets requirements of newest phosphate-free, ambient temperature conversion coatings
• Better cleaning capabilities than conventional immersion or spray
• Reduced floor space than conventional immersion
• Lower initial and operational cost than conventional immersion
• Huge labor savings through bulk feeder equipment
Coating small parts in bulk presents unique pretreatment challenges compared
to typical hanging systems.
• Spray provides good cleaning impingement on surfaces reached, but it is difficult to reach all parts
surfaces with spray in bulk.
• Conventional immersion requires very long dwell times to obtain adequate cleaning, rinsing and
conversion application.
• Conventional immersion for cleaning, in particular, requires long dwell to meet requirements for
newest phosphate-free, ambient temperature conversion coatings.
• Conventional immersion requires more space, higher initial investment cost and ongoing operational
costs than spray.
KOCH PRETREATMENT DELUGE addresses small parts pretreatment
challenges like no other process available!
George Koch Sons, LLC
www.kochllc.com
10 South Eleventh Avenue
Evansville, IN 47744 USA
Phone: 812-465-9600
Fax: 812-465-9676
UV Powder and Liquid
Demonstration Laboratory
To advance the increased customer interest in UV
powders and liquids on MDF wood, diecast metal
components, preassemblies, and other heat sensitive
substrates, KOCH recently completed a new UV
Powder and Liquid Demonstration Laboratory at our
Evansville, Indiana facility.
MDF panels preheated in IR/convection
oven before powder coating
The new lab equipment consists of a KOCH combination
electric IR/gas-fired convection oven for preheating and
melt/flow phases of the process, a new ITW Gema two-station,
manual powder booth, and ten Fusion Systems' microwavepowered U.V. lamps.
MDF panels enter UV curing zone.
Sample dimensions can range from kitchen cabinet doors to
large work surfaces for the office furniture industry. Larger
three-dimensional parts can be processed due to adjustable
side walls of the IR/convection oven and UV system.
Sample parts, MDF panels,
preassemblies and die cast metal
Hangable parts are transported with a variable-speed,
overhead, monorail conveyor system. Flatline conveying is
available to process smaller samples.
MDF panels transported by
overhead conveyor.
The KOCH demonstration lab is available "free of charge" to customers and their
suppliers. The lab facility offers excellent process development and process validation
to assure your new finishing system will perform as intended.
Koch UV Powder and Liquid Demonstration Laboratory
ITW Gema manual two-station
powder booth.
Koch lab technician displaying
UV powder coated panel
Koch Lab offers flatline processing
Two vertical rows of Fusion Systems'
microwave-powered UV lamps
KOCH electric IR/gas-fired convection
oven has adjustable side walls to process
wood panels or larger three-dimensional
components
Powder coated MDF panels enter
IR/convection oven for melt and flow phase
Fusion Systems' power supply modules
Fusion Systems' UV lamp with instant
on/off feature
George Koch Sons, LLC
10 South Eleventh Avenue • Evansville, IN 47744
812.465.9600 or 888.873.5624
Fax 812.465.9676
Home Page: www.kochllc.com • E-Mail: sales@kochllc.com
George Koch Sons Sales Team (L to R): Felix Cruz, Antonio Gallegos (Intl Sales),
Don Miller (Regional Sales), Steve Martin, Tom Neeley, Sam Woehler (Director),
Al Baum, Mark Horton (Regional Sales) and Ron Cudzilo (Regional Sales)