Gema Switzerland Introduces Pioneering Innovations

 

Leading Innovations from Gema Switzerland

As Mata Makine, we are the sole representative in Turkey for Gema Switzerland GmbH, offering comprehensive pre-sales and after-sales services. Gema Switzerland is a global leader in the field of electrostatic powder coating. The company provides solutions that meet the diverse demands and requirements of numerous customers worldwide across many industrial sectors, ranging from simple manual applications to fully automatic booth systems. Technologically advanced systems and equipment are manufactured at Gema Switzerland's headquarters in St. Gallen. The company's state-of-the-art laboratory in Switzerland is available for trial operations, and the reported results are then integrated into the design of the required systems to produce custom-tailored solutions for customers. This year, detailed information is provided below about the new powder coating center "OptiCenter All-in-One" introduced by Gema Switzerland, which will make a difference in the sector, and the new manual equipment "OptiFlex Pro," which stands out with its power.

OptiCenter All-in-One Powder Coating Transfer and Gun Control in One Unit

The most striking feature of the new OptiCenter All-in-One powder coating management center developed by Gema is that it combines powder coating feed and gun control in a single unit. Due to the elimination of the space-consuming control panel, the new powder coating center occupies significantly less space. At the same time, application, control and cleaning operations have been further simplified.

Figure 1: The powder coating center and controls are installed in minimal space in OptiCenter.

At first glance, you will notice that the latest generation OptiCenter control socket does not require hose connections or replaceable fittings. This is due to the new OptiStar All-in-One® control system. As an innovation in powder coating application, Gema has combined gun control and powder coating feed in a single center. Injectors are placed directly on the control unit, and pneumatic hoses between the injector and control unit have been eliminated. In this way, the space-saving system can be integrated with the powder coating management center, and up to 36 guns can be controlled and powder fed from a single location. The elimination of the space-consuming control panel allows for significantly less space consumption compared to other models.

Injector Integrated Directly into Control System – Single Unit Design

OptiFlow injectors featuring a single-piece cartridge design are directly integrated with the controllers into the OptiSpeeder powder coating hopper. The new injector provides continuous powder coating flow over a long period from a single piece, thus reducing maintenance and repair costs.

Figure 2: The OptiFlow injector (1) is part of the OptiStar All-in-One® control unit (2) and is mounted directly onto the OptiSpeeder powder coating hopper (3).

This feature has dramatically improved powder coating discharge timing. The integration of control and powder feed results in maximum cleaning efficiency and reduced powder discharge timing. Subsequently, the ability to control the powder cloud has improved coating quality and reduced powder consumption. All these features make the new system highly attractive for precise gap control requirements and robotic coatings. The internal monitoring system automatically detects irregularities that could cause transport problems in powder transfer and reports deviations to the system control. Powder coating flow is reliably maintained throughout the process to deliver optimal coating results. At the same time, proven PCC technology against powder accumulation and efficient powder discharge DVC technology are part of this system. By means of the 7-inch touchscreen on the OptiControl control system, OptiCenter application and monitoring, powder coating feed and fully automatic color change are performed. With new screen icons, the system has become more intuitive and easier to use. Efficient color change applied with bidirectional cleaning can be directed and monitored from the screen. After the start command is issued from the operation panel, the process is completed without manual hose changes or the need to move mechanical parts.

Figure 3: More intuitive, easier to use and more efficient – the OptiControl control system provides the operator with maximum comfort and safety.

 

OptiSpeeder Created for Excellence

The OptiSpeeder powder coating hopper fluidizes the powder at optimal values and delivers it to the guns via injectors through a closed-loop application. The wide lid opening on the hopper allows every point of the hopper to be visible. This also improves control during operation. Unlimited variable level sensors continuously monitor the powder coating level and feed powder inside. Even when working with small amounts of powder, feeding can be provided with high precision. The short suction distance is designed for optimal powder flow and best coating results.

Figure 4: The wide lid opening in OptiSpeeder allows for perfect observation and ergonomic access.

Switching between fresh and recycled powder coating feed is fully automatic and causes no downtime in hose changes. Efficient powder coating hopper cleaning is completely automatic. Through the touchscreen, the user can select different cleaning modes: "QualityClean" for cleaning between contrasting colors, "FastClean" for cleaning between similar colors, and "CustomClean" for special color change situations. As an option, Gema offers an ultrasonic sieve option for this design that provides freedom of movement. The sieve allows for gentle sieving of powder and is available in different sieve sizes.

OptiCenter All-in-One – Single Solution for All Needs

OptiCenter powder coating management and integrated OptiStar All-in-One® control units provide users with fast and high-efficiency color change, efficient coating results, clean working conditions, intuitive operation and seamless maintenance. The compactly designed system can deliver powder coating to up to 36 guns and is delivered pre-assembled and ready for use. With its modular design, it offers different feed options from a standard cone for fresh paint transfer to external 100-liter powder hoppers or big bag systems. OptiCenter All-in-One powder coating management center is much more than feeding systems developed by Gema. Today, it covers all the answers sought by users who want to apply permanently high-quality coatings with minimal effort and the most suitable economic solutions.

OptiFlex® Pro Power – Quality – Control

Gema delivers high power and performance with the new OptiFlex Pro manual powder coating application equipment. The PowerBoost function in the new OptiFlex Pro series delivers 110 kV high voltage and 110 μA charging current with a single button press. This significant increase in power makes it possible to apply any coating quickly and safely, even the most difficult to apply powders. OptiFlex Pro is designed to suit the industry, with ergonomics in mind. The newly developed PowerBoost technology in the OptiFlex Pro series delivers the highest powder coating loading capacity found in the powder coating industry while meeting safety requirements at 110 kV. PowerBoost is a system in which the OptiSelect gun, OptiStar 4.0 control unit and flat spray nozzle are completely interactive. All components are developed by Gema, and this technology developed for PowerBoost allows application over larger areas thanks to the intelligent spray capability of the powder cloud. High coating performance, DVC and PCC precision control functions and modern nozzle designs make the new OptiFlex Pro the ideal solution for every application. All OptiFlex Pro equipment is standard equipped with the OptiStar 4.0 control unit and is compatible with Gema E-App. Technicians and production managers can monitor efficiency, maintenance information, configuration and system data with their smartphones. The design and material selections for the new OptiSelect Pro gun have been renewed for the high-performance PowerBoost technology. When PowerBoost is activated, the user can apply additional powder whenever and wherever desired. Despite the power supply enabling high voltage up to 110 kV, the gun is lightweight and balanced, while also being durable and long-lasting. OptiSelect Pro and its nozzles are fully ATEX certified. As standard, the new OptiFlow IG07 injector is included on manual equipment. The new injector consists of a single consumable; with each cartridge change it can be used as if brand new. The OptiFlow IG07 injector has taken Gema's transfer efficiency and proven injector technology to the next level. Some OptiFlex Pro models can be used with the OptiSpray AP01.1 application pump. This allows the expectation of always stable powder coating transfer to be met. İsmail Akçurin - Sales and Marketing Manager - Sales and Marketing Manager - Mata Makine