Industrial Process Heating
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Andrew Pearson finds many benefits in change to electric infrared oven technology
Benefits to Andrew Pearson
Advanced Energy’s dedicated industrial process specialists have a passion for research and discovery. Our team provides direct access to in-the-field insight and innovative answers that generate practical solutions with measurable results. We have solutions for improving quality and productivity, reducing operating costs, environmental compliance, increasing capacity and extending equipment life. Background Andrew Pearson Design is a furniture manufacturer that sells to authorized dealers. Founded in 1990 in Troy, Mich., the company quickly gained a reputation for impeccable quality and tremendous flexibility because of its concentration on what other glass fabricators and furniture manufacturers could not create. In 1994, owners Hal and Sue Brownfield moved the company’s facilities to Mt. Airy, N.C., to be closer to furniture manufacturers. In 1999, Andrew Pearson Design acquired MET Collection for the Home, which created dynamic synergies that led to an expansion to double the size of its manufacturing plant. When the company wanted to introduce colored glass and decorative mirror lines, they anticipated that it would take two years to develop the process. Problem The Brownfields wanted to find a way to make color coating more durable and more adhesive. With no known experts in the field for coating glass applications, it seemed there was nowhere to turn. “We had two big challenges ahead of us. The first was testing to determine what equipment was needed, and the second was developing a process and making it work,” said Jimmy McMickle, distribution center manager. Jimmy remembered attending a past process heating workshop hosted by Advanced Energy. “Workshops are a good learning opportunity. I’m always interested in learning about ways to make products better, faster and, most importantly, cheaper.” He also had established a strong relationship with an industrial process specialist at Advanced Energy. With these resources in mind, Jimmy contacted the process specialist for assistance. Assistance Advanced Energy personnel knew that developing and proving a technique would be expensive and would require timely coordination. In addition, they would need a facility for testing, extensive testing time, knowledgeable equipment vendors and a classroom for providing training on the new process. These elements would ensure the proposed solutions were easily transitioned into production at Andrew Pearson Design. Solution Another big challenge was the production criteria that Andrew Pearson wanted to achieve. A successful production process meant they could produce larger quantities quickly. Vendors were brought in to help test existing equipment and to help propose the most efficient design for the equipment that would be used. During this testing phase, curing was reduced from 30 minutes for convection to four minutes for infrared heating. So, infrared (IR) technology was selected, and an IR oven was designed that would produce the affordable, attractive products that would carry the Andrew Pearson Design name. Vendors proved to be a wealth of knowledge, used the experience as a learning opportunity for themselves and shared in the desire and drive to develop the new process. Jimmy later stated, “If the vendors had approached me directly, I still wouldn’t have valued their expertise. It was the trusted relationship with the industrial process specialist at Advanced Energy that helped us meet our timeframe. This up-front trust was the key.” After the IR oven was designed and developed, other obstacles were to be overcome. How would the product be transported through the oven? How would overspray be prevented? How could heat be kept in the oven and not escape? Advanced Energy remained involved and provided additional coordination and guidance. Benefits With Advanced Energy’s assistance, Andrew Pearson Design created its Flaircote Process for colored glass and decorative mirrors. With this process and new equipment, the company achieved expected benefits, as well as ancillary benefits. Jimmy summarized his thoughts, “Andrew Pearson would not be producing our new product line today if not for the help from Advanced Energy. Working with Advanced Energy has saved us two years in legwork if we would have had to do testing on our own.” For More Information Contact Mark Gentry at 336-679-4020 or mgentry@advancedenergy.org.
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