Welcome: AEP Customers and Employees Energy Technologies October4, 2018 Electric Infrared Technology Industrial/Commercial Opportunities John Podach; SE Sales Manager Senior Application Sales Engineer
Fostoria Process Equipment A Division of TPI Corporation Welcome AEP Attendees About the Fostoria Process Equipment Division of TPI Corporation: A leader in the design, manufacture and sales of industrial process heating and finishing equipment Core products and expertise: Electric Infrared ovens and controls Convection oven systems Modular paint and powder finishing equipment Ability to provide all TPI products: IR comfort heaters, industrial fans/ ventilating products, unit heaters, wash down heaters, hazardous location heaters and more
Electric Infrared Marketing Opportunities Fostoria s two largest markets in general: Thermoforming Paint and Powder Curing Thermoforming consists of heating (preheating) a substrate material prior to forming. Forming is accomplished by compression (press) or vacuum forming in most cases. Major opportunities are in sales to the Tier One Suppliers to the automotive assembly plants. Substrate materials can be, among many materials: plastics, composites, recycled materials or honeycomb (cardboard-like) material. Fostoria ovens are currently used for thermoforming arm and head rests, headliners, floorliners, trunk and wheel well liners, heat/insulation barriers and other automobile parts.
Thermoforming continued... Market is approximately 50% of Fostoria s electric IR business Other T-forming markets include aircraft industry and smaller misc. manufacturing Greatest potential ADVANTAGES: Electric IR offers: Greatest control and flexibility in system design. Ability to zone Instant response prevents damage to product and best results BARRIERS: Use of non-electric power sources Generally will need to be in heavy manufacturing areas and/or located close to auto assembly plants Needs to be integrated with extensive material handling and loading equipment
Paint, Powder and Coatings Markets These markets represent approx. 25% of Fostoria s business Use electric IR to: Provide complete cure of paints, coatings and powders Pre-heat prior to convection cure Quickly gel powders Water dry-off prior to application of coatings Spot repair of imperfect finishes Create Hot Room Environments for air cure ADVANTAGES: Generally faster cures, smaller oven footprint (less space) Repeatable results with finite control and zoning Less capital equipment expense Efficient only on when required and provides instant start-up (vs gas convection)
Paint, Powder and Coatings Markets BARRIERS: Electric service (capacity) availability Electric IR not suited for all applications. Kw cost vs NG or propane?? Industry Allies include Powder Coatings Institute (PCI), Chemical Coaters Association International (CCAI) and as always, IHEA and the Infrared Division of IHEA (IRED)
Fostoria Electric Infrared Comfort Heaters for: Spot heat indoors Spot heat outdoors Snow/ice control Indoor comfort heat Indoor process heat (Hot rooms)
Fostoria Electric IR Oven Circa 1947 (below) and new (right) for same customer in Cleveland Cleveland OH 60 Kw IR heating load Cure coatings Portable w/casters Short-wave T-3 lamps
Examples of core Fostoria IR oven bank design with 900 Series heater sections can be configured side by side, end to end, etc, to form basic clam shell pattern or other pattern to fit the process LEFT: oven to be installed at a motor manufacturer to cure motor coatings; 120 Kw installed IR load with medium-wave IR quartz tubes RIGHT: oven installed in SC to pre-heat parts; 294 Kw heating load with flat panel medium wave emitters
Fostoria Specialized Ovens for Powder Coat Curing IR banks can be mounted on a caster/trolley system to widen or narrow the parts window profile. Water Dry-off and powder curing oven 792 total Kw Greenville, TN
Fostoria Electric Infrared Ovens in the Coatings Industry At right: Curing powder on fire extinguisher housings. Infrared is precisely zone controlled to direct the IR as required for proper cure. Instant response T-3 short-wave IR lamps are also accurately controlled via a closed loop control system that can ramp up or ramp down the IR intensity, to achieve required curing temperatures. Zoning and instant response combine to create a highly efficient, economical and fast curing process.
C Shaped configuration to cure coatings on heavy metal parts in Alabama Designed to accommodate a flat conveyor thru the oven for top/bottom heat 95 Kw electric IR heating load, with T-3 short-wave quartz lamps
Introducing AIR with Electric Infrared Testing and experience has shown that infrared in combination with air can greatly affect some processes, and thereby improve results, increase application efficiency and decrease time cycles. This photo shows how a blower can be back mounted to standard oven sections to create this combination. Air flows through the back and out the perforated reflectors in the front of the heater section. Blower mounted to back of heater section
Electric IR oven bank using mediumwave flat panel emitters 328 Kw IR heating load Oven to gel primer on welded frames Now installed in Chattanooga, TN
Thermoforming Systems present a huge opportunity in the automotive Tier One Markets. This system incorporates a 510 Kw Fostoria electric IR 2- station oven, pick and place material handling, a 250 ton press and transfer conveyors; to produce headliners for cars and pick up trucks. It is one of (3) systems installed for a total heating load of 1530 Kw for this new Tier One facility in San Antonio, TX.
Oven to preheat material prior to thermoforming (automotive) substrates. Two heat stations, top and bottom T-3 short-wave IR lamps PLC control panel (2) radiometers (top/bottom) for closed looped, automatic temperature control 243 Kw electric IR heating load
PLC based controls enable inputs for all temps and cycle times Thermoforming Ovens heat a variety of materials to form products in various markets
Electric IR to relax fabric, de-wrinkle leather, cloth or vinyl seats Electric infrared seat ovens and seat trim heaters have been used for decades to improve the final appearance of seats for all major automotive manufacturers. Fostoria has supplied these and similar ovens to all Tier One suppliers of seats in North American and many locations overseas. These ovens employ short-wave T-3 lamps for instant response and precise control to the various parts of the seat, to evenly relax and de-wrinkle the leather, cloth or vinyl.
Unique IR oven to preheat Tedlar material prior to vacuum forming airplane parts. Installed in SC 6 IR Zones - - Total load is 222 Kw
Portable and Modular Electric Infrared Banks for Coatings Cure powders, paints, coatings Gel powder prior to convection Portable booster system Water dry-off Modular system can be sized and configured for the application Easily positioned and removed for storage Variety of controls options All standard industrial voltages; short, medium or long wave IR heating elements can be used. Air is easily introduced to wick away moisture and create a gentle convective heat with the IR
Georgia CRC, Atlanta Combination convection oven (approx. 240 Kw) and 144 Kw medium-wave Infrared flat panel emitters total electric load 384 Kw. (8) 18 Kw flat panel emitters are mounted to the walls of the oven for combination heating 240 Kw convection heat in a pass thru Fostoria oven
Thank You!