1998 Large Coating Job Shop Survey

Article From: Products Finishing, , from Gardner Business Media

Posted on: 8/1/1998

The economic upswing of previous years has hit these large coating job shops...

As the first half of the age-old adage goes, the rich get richer. Large coating job shops certainly had a great year in 1996, but it appears that 1998 will be even better for the large paint/powder coating job shops that responded to the biennial survey conducted by Products Finishing. Many of these large coating job shops showed a dramatic increase in one of four categories: number of employees; annual sales; number of facilities; and sq ft of finishing plants. Although these four categories may not directly correlate to economic growth, the results showed that the recent economic boom in this country has hit this sector of the finishing industry.

In addition to asking job shops about their facilities, we asked two other questions:

What challenges will your business face in the next five years?

What will be the predominant coating required by customers in the next five to 10 years?

The first question provided some interesting answers. The two main challenges most job shops thought they would face are finding qualified and skilled individuals to work in their plants and meeting future environmental regulations and recording requirements. Finding qualified and skilled employees is not just a problem for the finishing industry, but for other manufacturing industries as well, especially with the current low unemployment rate.

Other challenges facing these large coating job shops are increasing quality demands, maintaining profit margins, consolidation or a downturn in the automotive industry and controlling growth. Maintaining profit margins and a downturn in the automotive industry are certainly serious concerns for these job shops, especially in light of potential economic problems and the amount of business these large job shops conduct with the automotive industry.

Despite a potential slow-down of the U.S. economy and automotive finishing market, large job shops that perform powder-coating operations have something to anticipate. Virtually every one of the companies that responded to our survey thought powder coating would increase its market share in the next five to ten years, especially in the automotive sector.

The use of powder coatings is expected to increase for several reasons. First, with future environmental regulations looming over the heads of many coaters, powder coating is an operation that is environmentally friendly. Powder coatings do not contain any solvents and, therefore, release no VOCs to the atmosphere. In addition, the waste powder from a painting system is easy to dispose of since it is not a hazardous or regulated waste. Second, the automotive industry is poised to make a huge leap into powder coating.

BMW is currently using powder coatings for the clear coat on production cars that are painted in its Dingolfing, Germany, plant. The auto manufacturer has proven that it is economically feasible to use powder coatings for clear coating in the real world. Not only is BMW using powder coatings for the clear coat, there is a possibility it may use powder coating for the color coat also.

Because BMW is a leader in the automotive industry, it is likely that other European automakers will follow BMW's lead. This is important for the U.S. finishing industry because European automakers are beginning to move some of their plants to the U.S. (BMW, Spartanburg, South Carolina, and Mercedes, Tuscaloosa, Alabama). As BMW and other European automakers build more plants in the U.S., it is highly possible that they will bring the finishing technology they use in Europe to production lines in the U.S.

It is not only European automakers that are beginning to make the switch to powder though. The use of powder coatings is so important that the Big Three have created a joint research project (USCAR) to determine the feasibility of using powder coats for clear coating. Although the switch to powder coating is not expected for another 10 to 20 years in the U.S. auto market, it is just a matter of time. As environmental regulations get tougher and U.S. automakers build new plants, it is likely that powder coating will become the standard.

The sidebars below highlight each company that responded to this year's survey. If you are or know of a company that should be included, let us know.

Metokote Corp.
Lima, Ohio
419-227-1100
Fax: 419-224-1043
Employees: 1,522
Annual Sales: More than $100 million
Facilities: 24
Combined Sq Ft: 2.1 million
Substrates: Steel, aluminum, plastic, magnesium
Pretreatment: Iron and zinc phosphate, chromate, zinc
Coatings: Conventional solvents, electrocoating, powder, waterborne, specialty material
Application Techniques: Air-assisted-airless spray, air-atomize spray, airless spray, electrocoat, electrostatic spray
Curing System: Convection, infrared, UV
Vulcan Group
Bessemer, Alabama
205-424-2267
Employees: 200
Annual Sales: $10 to $15 million
Facilities: 3
Combined Sq Ft: 480,000
Substrates: All
Pretreatment: Zinc and iron phosphate, sandblasting
Coatings: Conventional solvent, electrocoating, high-solids, powders, waterborne
Application Techniques: Air-assisted airless spray, air-atomize spray, airless spray, dip coating, HVLP, electro-coating, electrostatic spray, fiberglass spray, hot spray
Curing System: Convection


The Crown Group
Warren, Michigan
810-575-9800
Employees: 800
Annual Sales: $50 to $100 million
Facilities: 7
Combined Sq Ft: 700,000
Substrates: All
Pretreatment: Zinc and iron phosphate, plastic clean and prep Coatings: Conventional solvent, electrocoating, high-solids, powder, waterborne, lacquer
Application Techniques: Air-assisted airless spray, air-atomize spray, airless spray, HVLP, electrocoating, high-speed rotational bells, and electrostatic spray
Curing System: Convection, high-velocity, infrared

Springco Metal Coating, Inc.
Cleveland, Ohio
216-941-0020
Fax: 216-941-9712
Employees: 246
Annual Sales: $10 to $15 million
Facilities: 2
Combined Sq Ft: 130,000
Substrates: Steel, aluminum, others
Pretreatment: Zinc phosphate
Coatings: Powder, electrocoating, zinc electroplating
Application Techniques: Electrocoat, electrostatic spray, blow coating, electroplating
Curing System: Convection

Acme Finishing Co., Inc.
Elk Grove Village, IL
847-640-7890
Fax: 847-640-0298
Employees: 110
Annual Sales: $5 to $10 million
Facilities: 1
Combined Sq Ft: 110,000
Substrates: Steel, aluminum, aluminum and zinc die castings
Pretreatment: Iron phosphate
Coatings: High-solids, powder, waterborne
Application Techniques: Air-atomize spray, dip coating, HVLP, high-speed rotational bells, electrostatic spray
Curing System: Convection, infrared

Russell Products
Cleveland, Ohio
216-267-0880
Fax: 216-433-1901
Employees: 70
Annual Sales: $5 to 10 million
Facilities: 6
Combined Sq Ft: 90,000
Substrates: All
Pretreatment: All
Coatings: Conventional solvent, electrocoating, high-solids, powder, waterborne, lacquer
Application Techniques: Air-assisted-airless spray, airless spray, dip coating, HVLP, electrostatic spray, hot spray
Curing System: Convection, infrared

All Metals Processing
Stanton, California
714-828-8238
Employees: 187
Annual Sales: $10 to 15 million
Facilities: 1
Sq Ft: 20,000
Substrates: Aluminum, plastic, steel
Pretreatment: Solvent phosphate, chemical film, anodize, cleaners
Coatings: Conventional solvent, high-solids, powder coating, waterborne and lacquer
Application Techniques: Air atomize spray, dip coating, HVLP, electro-coating, electrostatic spray
Curing System: Convection

B.L. Downey, Inc.
Broadview, Illinois
708-345-8000
Employees: 235
Annual Sales: $15-20 million
Facilities: 1
Sq Ft: 260,000
Pretreatment: Zinc phosphate, shot blast
Coatings: Electrocoat, powder coating
Application Techniques: Electrostatic spray, dip coating, electrostatic dip

General Magnaplate
Linden, New Jersey
908-862-6200
Employees: 200
Annual Sales: $10 to 15 million
Facilities: 5
Coatings: Electrocoating, powder coating, waterborne
Application Techniques: Air-atomize spray, electrostatic spray
Curing System: Convection

DV Industries, Inc.
Lynwood, California
213-563-1338
Fax: 213-567-7130
Employees: 150
Annual Sales: $15 to $20 million
Facilities: 2
Combined Sq Ft: 170,000
Substrates: Aluminum, titanium, and stainless steel
Pretreatment: Anodizing, phosphate fluoride
Coatings: Conventional solvent, waterborne
Application Techniques: HVLP
Curing System: Convection

Metal Cladding, Inc.
Lockport, New York
716-439-4010
Employees: 95
Annual Sales: $5 to 10 million
Facilities: 1
Sq Ft: 390,000
Substrates: Steel, aluminum, brass, copper
Pretreatments: Zinc phosphate, grit blast, Alodine
Coatings: Conventional solvents, high-solids, powder coating, waterborne
Application Techniques: Air-assisted airless spray, air-atomize, dip coating, HVLP, high-speed rotational bells, electrostatic spray, flow coating, hot spray
Curing System: Infrared, convection

Industrial Powder Coatings, Inc.
Norwalk, Ohio
419-668-4436
Employees: 650
Annual Sales: More than $40 million
Facilities: 7
Combined Sq Ft: 525,000
Substrates: Steel, aluminum, plastics, alloys
Pretreatment: Zinc and iron phosphate
Coatings: Powder, electrocoating
Application Techniques: Electrocoat, electrostatic spray, and robotics
Curing System: Convection, infrared

Brainerd Industries, Inc.
Dayton, Ohio
937-228-0488
Fax: 937-449-8057
Employees: 100
Annual Sales: $5 to $10 million
Facilities: 1
Sq Ft: 70,000
Substrates: Steel, aluminum
Pretreatment: Various
Coatings: Conventional solvent, powder
Application Techniques: Electrostatic spray, roll coating
Curing System: Convection, infrared

Linetec Co.
Wausau, Wisconsin
715-843-4100
Employees: 300
Annual Sales: $20-30 million
Facilities: 2
Combined Sq Ft: 150,000
Substrates: Steel, aluminum, plastic
Pretreatment: Chromium phosphate
Coatings: Conventional solvent, waterborne, lacquer
Application Techniques: air atomize spray, HVLP, high-speed rotational bells, electrostatic spray
Curing System: Convection and infrared

Centria
Cambridge, Ohio
740-432-7351
Employees: 100
Annual Sales: $15 to $20 million
Facilities: 2
Substrates: Stainless steel, cold-rolled steel, galvanized steel, galvalume, aluminum
Coatings: Conventional solvent, waterborne
Application Techniques: Coil coating
Curing System: High velocity

American Coating Technologies
Greenville, North Carolina
919-758-8998
Fax: 919-758-3791
Employees: 97
Annual Sales: $5 to $10 million
Facilities: 1
Combined Sq Ft: 60,000
Substrates: Steel, zinc, aluminum
Pretreatment: Zinc phosphate
Coatings: Electrocoating, powder
Application Techniques: Electrocoating, high-speed rotational bells
Curing System: Convection
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