April 10-12, 2012

Orlando, FL


Don’t miss ECOAT 2012, the industry’s most crucial event, giving attendees the opportunity to learn from suppliers and end-users; stay current with trends in the economy, new methods of managing electrocoat systems; learn about new technology and applications; and meet and network with industry colleagues. ECOAT 2012 is an educational conference for everyone involved in the electrocoat business and for people interested in learning about electrocoating.
 

Join us for this two-day event featuring dynamic keynote speakers, concurrent programming choices, and interactive workshops. Workshops will address topics such as advances in pretreatment, understanding the challenges of system optimization to maximize profit and minimize cost, and enhancing the performance of e-coat finishes. Back by popular demand is the Industry Awards Luncheon to honor the industry’s elite. New this year will be Coatings and Cocktails, a roundtable discussion opportunity to “ask the experts” about the industry, the technology and industry advancements while having a drink on us!
 

A specially built curriculum will help broaden attendees’ knowledge base. Attendees will be equipped with the knowledge to analyze and improve their systems to make an immediate impact on their business. See our website at www.electrocoat.org/conference for the complete details as they become available. In addition, Exhibit Rooms offer attendees direct access to suppliers of equipment, chemicals, paint, ancillary equipment and finishing applications in a fun, relaxing environment.
 

Scheduled for April 11-12, 2012 at the Rosen Centre Hotel in Orlando, FL, ELECTROCOAT 2012 is sponsored by THE ELECTROCOAT ASSOCIATION and PRODUCTS FINISHING magazine.
 

All registered attendees will receive a Conference notebook and a CD-ROM of the Conference Proceedings. Presentations will also be available online prior to and after the Conference for paid attendees. Continental breakfasts, refreshment breaks and the Industry Awards Luncheon are also included.
 

For complete details, contact Anne Von Moll, Conference Assistant, ELECTROCOAT 2012, 6915 Valley Avenue, Cincinnati, Ohio 45244 USA. Telephone: 513.527.8800 or 800.950.8020, ext. 298; fax: 513.527.8801;
e-mail: anne@electrocoat.org. To Learn More: http://conference.electrocoat.org/

 

Tuesday, April 10, 2012

Meet & Greet Pool-Side Reception, hosted by The Electrocoat Association

Wednesday, April 11, 2012

7:30 a.m. - Conference Registration & Information Open


7:30 - 8:30 a.m. Continental Breakfast

8:30 - 10:00 a.m. - General Conference Opening &
Keynote Address

10:15 - 11:30 p.m. - Innovations in Pretreatment Session

11:45 - 1:15 p.m.- Industry Awards
Banquet

1:30 - 4:20 p.m. - Concurrent Workshops


4:30 - 5:30 p.m. - Coatings & Cocktails

5:30 p.m. - Exhibit Rooms Open For Hospitality

Thursday, April 12, 2012

8:30 a.m. - Conference Registration & Information Open

8:30 - 9:00 a.m. - Continental Breakfast

9:00 - 10:15 a.m. - General Conference Session & Keynote Address

10:30 - 12:00 noon - Weathering the Economic Storm Session

12:00 - 1:15 p.m. - Lunch

1:30 - 3:20 p.m. - Concurrent Workshops

3:30 - 4:30 p.m. - Efficiency/Environmental Session & Closing Remarks

 

 

CONFERENCE PROGRAM

Wednesday, April 11

8:30 - 10:00 a.m. - General Session #1
Conference Opening and Welcome


Keynote Presentation
What Underperforming Finishers Don't Know
(That the Good Ones Do)
Matt Kirchner, American Finishing Resources, LLC

Underperforming finishing operations are not failing by accident.  Underperforming finishers haven’t learned how to build the best teams.  Their people don’t understand and don’t obsess about throughput.  They don’t know how to identify waste.  They expect less of their suppliers.  They overcommit and under deliver.  Their sales and operations functions spend more energy fighting each other than fighting the competition.   By contrast, World Class Finishing Operations do exactly the opposite. Whether you own or lead a finishing operation or department - or serve as a supplier to one – this presentation reveals the secrets that the best performing finishers already know.
Matt Kirchner Biography
Matt serves as the Chief Executive of American Finishing Resources, LLC (AFR). With facilities in Wisconsin, Iowa and Indiana and a transportation footprint encompassing twelve states, AFR is the largest provider of Industrial Coatings Removal and Paint Fixture and Hanger Fabrication in the Midwest. In addition to his role with AFR, Kirchner is President of Profit360, LLC, a Midwest provider of management advisory services, and speaks frequently on topics of interest to American manufacturers and those who serve them.
For 10 years prior to joining AFR, Kirchner served as the President and Chief Executive Officer of ABQC Corporation, a large metal finishing operation located in Milwaukee, Wisconsin. In the mid-1990’s Kirchner completed the turnaround of Innovative Control Systems, Inc. a Wisconsin corporation that develops and manufactures high-tech security and asset protection systems for healthcare facilities.
He is a licensed Certified Public Accountant and serves on the boards of directors of three corporations and several non-profit organizations.
Kirchner is past President of the Milwaukee Branch of the American Electroplaters and Surface Finishers Society and presently serves on its Board of Managers. He also served as the Co-Chair of the Management Committee of the National Association for Surface Finishing. He has been recognized in the Milwaukee Business Journal's “40 under Forty”, honoring leaders under 40 years of age who have succeeded in business and given back to the community. He is a graduate of Marquette University and the author of “Never Finished,” a monthly management column appearing in Products Finishing magazine.
10:00 - 10:15 a.m. - Break

10:15 - 11:30 a.m. - Innovations In Pretreatments

Learn what's new in Pretreatment. Bring your questions!
Recent Advances in Surface Preparation Technology
Randy Brent & Jack McIntyre, PPG Industries Inc.
 
Never before has surface preparation been so important since the introduction of thin film pretreatments. Thin film pretreatments, such as zirconium, are more sensitive to proper cleaning and surface activation.  This discussion will explore single and multi-step cost effective chemistry approaches to improve coating performance of laser cut edges, removal of aged & varnished soils, preparation of multiple substrates; CRS, galvanized steel, aluminum, and cleaning at low temperatures.
 
Advances in Metal Pretreatment
Bruce Goodreau, Henkel Technologies
 
Zirconium-based pretreatment systems have been introduced to the electrocoating industry over the past several years. The new systems are based on zirconium oxide rather than iron or zinc phosphates. Zirconium oxide pretreatments have very a different deposition mechanism, coating characteristics, and electrocoat requirements compared to zinc or iron phosphate. The basic chemistry of these processes will be reviewed with a focus on paint adhesion and corrosion protection. In this paper we present an update on the development of this new metal pretreatment technology.
 
Organic / Inorganic Advanced Pretreatments
Suresh Patel,  Chemetall US Inc.
 
New pretreatments with operational and cost advantages will be described as well as a practical explanation of how a finisher can make a change to these new technologies.  Silane chemistry will be reviewed, focusing on factors to consider when choosing this pretreatment method.
  
CASE STUDY:   The Effects of Changing Cleaner and Metal Treatment Chemistry
Ken Kaluzny, Coral Chemical Company
 
This case study will focus on the effect of pretreatment changes on salt spray corrosion resistance for a construction equipment company.  The pretreatment sequence was progressively modified from utilizing alkaline cleaning and iron phosphate pretreatment system to alkaline cleaning and zirconium treatment and then finally to acid cleaning and zirconium treatment.   Salt spray corrosion resistance results will be covered as well as other process concerns encountered during the pretreatment process conversions. 

11:45 - 1:15 a.m. - Industry Awards Banquet

George E.F. Brewer Award
This prestigious award recognizes individuals who have made lasting contributions to the field of electrocoating in the areas of Technology, Application, and Promotion.

Best End-User Paper Award
This award is a tribute to e-coaters who have devoted their time and company resources to procduce technical presentations for the Conference.
Concurrent Workshops

1:30 - 2:20 p.m.
#1 - The Profit Hunt:Competing In Deflationary Times
TJ Lepkowski and Chuck Orr, BASF
Operating a profitable e-coat system is more than just hanging and painting parts. The e-coat system must be optimized for maximum profitability. In this presentation, we’ll show you how to do exactly that by:
  • Optimizing the system for maximum efficiency, even when product technical limitations exist
  • Identifying and removing process bottlenecks
  • Evaluating the cost of material variables beyond paint
  • Understanding and defining the total cost to coat parts
This presentation will help E-coaters understand the challenges of system optimization to remove bottlenecks, improve efficiency and understand total costs
#2 - Lose The Agitation
Casey Sample , PPG Industries

A recent trend in electrocoat includes the use of anti-settling products that allow circulation pumps to be turned off during non-production hours.  The ability to shut down pumps for nights and weekends to reduce electricity consumption has the potential to trim electricity costs and lessen the system’s carbon footprint, provided the formulation has been specialized for stability.  Most of these fairly new anti-settling electrocoat products include additives that aid in the suspension of typically fast-settling pigment particles.  However, anti-settling electrocoat has been used for over a decade by simply taking advantage of conventional low-density pigmentation and following basic procedures to minimize equipment issues upon restart of the system.
2:30 - 3:20 p.m.
#1 - Adding E-Coat To An Existing Powder Coating Line
Joe Subda, DuPont

Today’s competitive environment has made it very challenging for coating companies to improve financial results by capturing larger market share, and nearly impossible to do it through price increases.  In fact, it is not unusual for coating companies to reduce prices to retain business.  Coating companies must reduce costs and improve productivity and quality to remain competitive and increase profitability.  But even this may not be enough for some coaters.  Companies that only supply one or two types of coatings may need to add others to experience growth and expand into new markets.  Manufacturers are making products that require a range of coatings and will look for suppliers that can fulfill their varied needs.  Coaters that can offer multiple coating options for their customers will have the best chance of gaining new business.

#2 - Using A Zinc Rich Base Coat To Enhance The Performance Of Electrocoat Finishes
Kelly Moore and Matthew Scott, PPG Industries
For many years electrocoat has been used on various substrates to improve the corrosion resistance of finished parts. Typically the parts are made of steel or galvanized steel and finished with electrocoat. Recently OEMs and part manufacturers have implemented strategies for part weight reduction, base metal thickness reduction, and increased welded component parts, all while trying to control the cost of the manufactured part. These changes have put a focus on ensuring that the finish used on these parts conveys the best performance characteristics to meet stringent requirements for the automotive and industrial markets. To improve the performance of electrocoat on these new breed of parts, zinc rich base coats have been used in conjunction with electrocoat. This duplex coating has proven to be a viable and cost effective solution that meets or exceeds performance expectations.
This workshop will investigate the zinc rich base coat chemistry, the mechanism that improves the corrosion resistance, the application techniques for the zinc rich product and the improved performance characteristics of the zinc rich and electrocoat finish.
#3 - E-Coat Opportunities With Military Components
George Lovell, NCP Coatings, Inc.

Cleaning, Pretreatment, Primer, and Top Coat are all terms/process steps that those in the E-Coat world are familiar with. Cleaning, Pretreatment, Primer and Top Coat are also terms/process steps that are used in Chemical Agent Resistant Coatings (CARC) painting of military components, small and large. This presentation will point out how Cleaning, Pretreating, Priming and Top Coating are inter-related in the world of E-Coat painting and CARC painting and what it will take to expand your E-Coat business in to CARC painting.
3:30 - 4:20 p.m.
#1 - Water Use And Reuse In The Finishing Industry
Tom Neeley, George Koch Sons, LLC

#2 - Colored E-Coat Options For The Heavy Duty Equipment Industry
Robert Byrne, PPG Industries
Interesting developments in the use of colored electrocoat for the Industrial market are bringing innovative approaches and improvements in the areas of productivity, quality and cost. In this challenging economic environment, innovative alternatives that acknowledge quality and performance are a way to succeed with profitable growth. The use of colored electrocoat is one such innovation.

4:30 - 5:30 p.m. - Coatings & Cocktails

Participate in an extreme version of theme rotation as you move from topic to topic, table to table through an electrocoating process, asking experts questions about new products, new processes or even about your own system. We'll cover every aspect of your system process from masking to material handling, equipment to paint and chemistry to ultrafiltration - all while sipping a complimentary cocktail. Custom coaters will be available for general business questions.

5:30 p.m. - Exhibits Open

Thursday, April 12

 
9:00 - 10:15 a.m. - General Session #2
Opening and Welcome
Keynote Presentation
A Manufacturing Renaissance
Al Stimac, President, Manufacturers Association of Florida

Manufacturing in the United States is reinventing itself to better compete globally. Manufacturers are taking a more personal responsibility for the continuity and long term growth planning of the industry.

Al Stimac Biography
President, Manufacturers Association of Florida
Chairman, Global Talent Competitiveness Council, Workforce Florida Board of Directors
Owner & President, Metal Essence Inc. and Machining Solutions
A self-made industrial leader, Al Stimac is the personification both of entrepreneurial spirit and of the American Dream.  At the age of 16, Al began an apprenticeship in precision sheet-metalworking with the Stromberg-Carlson division of General Dynamics. For the next 25 years he advanced through a series of increasingly demanding management positions and a series of mergers and acquisitions. In 1995 he left his position as Vice President and General Manager of Comtel Metal's Lake Mary, FL plant to concentrate on growing his own business – Metal Essence Inc. – which rapidly expanded to a workforce of over 80.

The company specialized in production of high volume, high tech parts used in the automotive, aerospace and electronics industries and grew to be an effective competitor in the global marketplace. In 2006, Stimac started a consulting business, Machining Solutions, LLC. He now travels to other machine shops and increases their productivity, training and machine tool issues while reducing overall costs by using a unique systematic engineering approach. These improvements help to retain manufacturing sources not only in Florida but in the United States.
Al Stimac has had a career-long record of giving back, both to the community and to the manufacturing industry. A past member of the Board of Directors of the United Way of Central Florida, Stimac chaired the annual campaign in 1986, raising what was then a record amount for the program. Al has been among the most ardent supporters of workforce development in Florida, having been appointed to the Workforce Florida Board of Directors in July 2008 and reappointed in August 2011. He has served as President of the Board of the Manufacturing Association of Central Florida (MACF) and continues to serve as a board member. He has been President of the Manufacturers Association of Florida since 2005.
Over the years, he has been tireless in his efforts to explain the benefits of a manufacturing-based economy to both state and Federal legislators, regulators, chambers of commerce and other business interests. Mr. Stimac champions the notion that manufacturing helps maintain a diverse economy; creates and sustains high-paying jobs; promotes investment in capital equipment, research and development; and generally helps build and maintain a superb quality of life for those employed in the industry and for the larger community from which they purchase goods and services. In order to accomplish these goals he also sits as a board member of the Orlando Regional Chamber of Commerce, the Florida Chamber of Commerce and the National Association of Manufacturers.
10:15 - 10:30 a.m. - Break

10:30 - 12:00 Noon
- Weathering The Economic Storm...Learn From The Greats

In this compelling session you'll hear from industry custom coaters and end users on how they've responded to the economic challenges of the last several years. They will share innovative ideas and solutions used in their manufacturing line-up that have led to cost savings, increased effiency or new profit generation in response to these tumultuous economic times.
12:00 - 1:15 p.m. - Lunch


Concurrent Workshops

1:30 - 2:20 p.m.
#1 - Quantum Throughput Maximization (QTM)
Matt Kirchner, American Finishing Resources, LLC
In his keynote address, Matt Kirchner of American Finishing Resources, LLC and Profit360, LLC revealed that the very best finishers don’t just understand finishing line throughput – they OBSESS about it. Maximizing the throughput of a finishing line (maximum volume of conforming product coated in the minimum amount of time) is the single biggest key to increasing the profitability of a finishing operation. Participants in this session will learn the basics of Quantum Throughput Maximization© (QTM), a step-by-step process that can be used by finishers and their suppliers to generate rapid and significant improvements in line density, yield of conforming product and, as a result, profit.
#2 - Building An Energy Cost Model For Electrocoat Systems
Gary Orosz, PPG Industries

When considering the purchase of an electrocoat system, it is often desirable to estimate the primary costs associated with operating the system.  These costs are those mostly associated with labor, electrocoat and utility consumption.  In the absence of completed engineering specifications it may not be possible to get information on the individual components, such as rectifiers, pumps and ovens, which would allow one to estimate how much energy they will each consume.  As a result, it becomes necessary to look at production requirements and basic electrocoat design guidelines to build your own energy cost model.

2:30 - 3:20 p.m.
#1 - AACD And What It Can Do For Your Company
Mike Arnold , Controlled Power Company

The AACD is an automatic voltage controller and paint usage optimizer for batch, hoist and conveyor e-coat systems. The AACD greatly narrows film variances between various sized parts providing greater film tolerances. The AACD addresses issues such as under/over coating, excessive paint usage, excessive power consumption and bath temperature issues.

#2 - In-Process Temperature Profiling - Understand, Control
And Optimize Your E-Coat Oven
Brad Colie, Datapaq and Terry Ray, KMI Systems

This discussion will focus on the importance of having a well-balanced oven and the tools and methods necessary to analyze and correct one.  Some basics on temperature profiling will segue into a presentation of examples in the industry of using tools to improve oven performance.

3:30 - 4:30 p.m.
Closing Session - Going Green, Running An Efficient System,
And Reducing Costs
Roger Talbert, The Powder Coating Institute

There is a lot of interest in “green” technology based on environmental awareness. Cleaner air and water is good for us but cost savings in the process makes it even more interesting. The presentation will focus on efficiency and change to reduce operating cost while also reducing environmental impact. It will look at the coating process as well as the plant environment.

 

Conference Adjourned

 

 

 



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