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Case Studies

 
Problem Solved!

Here’s a project a single individual performed showing the complete transformation of the exterior of a garage:


The completed restoration has a finish that will last for many years to come. The entire project was completed by a single individual over the course of two days.”

 

 
Rustic Siding System Case Study Nature of the Problem:

This project was completed in July of 2009 and consisted of the surface restoration of an extremely weathered garage. The garage had two sides that were refaced with exterior panel siding but were left unfinished for several years. These surfaces were extremely grayed and stained by mold and mildew. The restoration steps are described below with photos illustrating the progress.

Procedure:

A deck wash was applied, along with the GL-6400 basecoat sealer and GL-6800 topcoat.

Resolution:

View this full case study»

 

 

Problem Solved!

Here’s a project a single individual performed showing the complete transformation of the exterior of a garage:


The completed restoration has a finish that will last for many years to come. The entire project was completed by a single individual over the course of two days.”

 

 
Door Systems Case Study Nature of the Problem:

Blisters are occurring on doors that are of oak veneer and are stained dark. The problem occurs at least 25% of time. The net result of blistering requires re-sanding and refinishing. Most times this will correct the problem but sometimes the entire process needs to be repeated a third time.

Procedure:

Doors sanded 120 – 150 grit

1st pass

  1.  Sanded at Ernst 220 grit and denibbed
  2.  Stain coat applied and wiped for open grain woods
  3.  Conventional oven dry at 200oF
  4.  Scuffed and dusted
  5.  UV sealer applied (reverse or stopped doctor)
  6.   UV cure 200W/300W

2nd pass

  1.  Scuffed and dusted
  2.  UV sealer applied
  3.  UV cure 200W/300W

3rd pass
Scuffed and dusted
UV top coat applied
UV cure 200W/300W
BLISTERING PROBLEM: Blistering occurs on dark stained woods

Resolution:

1. Using ASAC™ technology, a GreenLight Coatings™ self-sealing 100% active, UV curable coating product was provided for the flatline, roll coat process.

2. First action was to evaluate the 2 lamp UV oven energy density profile (mJ/cm2): The power to the lamps was reduced from previous settings (as guided by the use of an EIT UV radiometer).

First Lamp 125 W/in; Second Lamp 200 W/in
Right Center Left
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3. The resulting total applied dry coating thickness was determined to be between 1.5mil and 2.0mil.

4. The finish appearance achieved was remarkably smooth and of high quality. It was observed that the open grain, recessed stained areas of the wood veneer (in this case red oak) did not receive applied seal or topcoat during the roll coat process. These regions, specifically with the use of dark stains, tend to appear duller in contrast to the surrounding topcoated, finished surfaces. A brush roller was installed and used to “work” the seal coat into the grain and corrected and improved visual appearance.

5. The final sheen was measured to be between 30 and 35 and blistering was eliminated.

 
Problem Solved!

Here’s what the door systems manufacturer has to say:


“We needed assistance with a Dubois flatline, roll coat system running a UV curable sealer and topcoat. We run the system to finish architectural doors and plywood. GreenLight Coatings™ was able to make us a self-sealing topcoat that has performed 100%. Coating has become a non-issue, since we started using GreenLight Coatings™, 4 years ago.
I know i made a good buying decision, when a material is never brought up in a production meeting!


R. P., Owner

 
Problem Solved!

Here’s what the manufacturer of hardwood flooring has to say:


Van Technologies has been a great partner to our company for many years.  They have provided creative coating solutions, have helped us design appropriate test parameters to validate their products compared to our competition, and have helped us meet very challenging end user pricing requirements.  I have zero reservations about picking up the phone and asking their team for help, and knowing that what they provide will either be a “win, win” solution or a stepping stone to a “win, win” solution.
They simply get it, and represent exceptional customer service in all they do.  They are a trusted partner.”


L. P., Executive

 
Hardwood Flooring Case Study Nature of the Problem:

The production rate of manufactured, prefinished quartersawn oak flooring was limited. A UV curable process was desired to ramp up production speed to support increases in demand. The flooring requires maximum durability to support heavy traffic in commercial and industrial installations. Further, space limitations allowed only 1 applications station and 1 UV cure oven. A single coat 100% UV curable finish is required to solve the problem.

Procedure:

The customer currently utilizes a spray system to deliver a waterborne latex type coating to the hardwood flooring in a lineal line format.

Once the current coating is applied, the flooring is permitted to air dry upon a lateral conveyor having significant ambient airflow to facilitate the process. The resulting time to complete finishing is insufficient relative to the demand for product.

Resolution:

1. A complete review of the flooring specifications was performed and the manufacturing facility was scoped for UV finish line installation.

2. It was determined that the available space would permit a single head UV roll coat finishing operation to be installed.  Expansion at other facilities would follow with success at the initial facility.

3. Selection of application and cure equipment was supported by Van Technologies

4. Onsite training for all operators and qualtiy personnel was provided by Van Technologies

5. A second line was installed at another facility due to the success achieved at the initial location

6. The GreenLight Coatings™ product engineered via ASAC technology provided conformance to performance specifications.

Problem Solved!

Here’s what the manufacturer of hardwood flooring has to say:


Van Technologies has been a great partner to our company for many years.  They have provided creative coating solutions, have helped us design appropriate test parameters to validate their products compared to our competition, and have helped us meet very challenging end user pricing requirements.  I have zero reservations about picking up the phone and asking their team for help, and knowing that what they provide will either be a “win, win” solution or a stepping stone to a “win, win” solution.
They simply get it, and represent exceptional customer service in all they do.  They are a trusted partner.”


L. P., Executive

 
Building Component Case Study Nature of the Problem:

A building products manufacturer experienced problems associated with the finishing of linear wood components used in the architectural moldings, millwork and window component markets. The finishing process applied a waterborne primer and paint topcoat and was suffering consistency issues in surface gloss, color, and blemishes due to film softness/block sensitivity. The reject ratio and requirement for rework was unacceptable creating bottlenecks in production and lost profits.

Procedure:

Primer and paint topcoat are applied using an automated lineal line system incorporating Graco Compliant Technology air spray guns.

The line speed is 185 fpm through the spray booth whereupon parts are transferred to a lateral oven conveyor at 15 fpm for a dwell time of 3 min.

The lateral oven conveyor is equipped with 3 zones as follows:

  1. Zone 1: ambient air flow for 1 min
  2. Zone 2: 3 IR lamps to bring component part temperature to maximum temperature of 140oF; 1 min dwell time
  3. Zone 3: ambient air flow for 1 min

Components are immediately stacked at end of oven conveyor and either delivered to assembly or packaged for shipping.

Resolution:

1. A waterborne GreenLight Coatings™ primer and paint topcoat was engineered using ASAC Technology to provide conformance to KCMA and WDMA requirements.

2. The GreenLight Coatings™ primer and paint topcoat exhibited the following properties:

  1. Complete dryness via the oven profile of the process
  2. Non-Blocking
  3. Consistent gloss to specification, batch to batch (past 10 years)
  4. Color consistency batch to batch (ΔE = 0.6 ∓ 0.1 (past 10 years)

3. The reject ratio and rework is no longer any concern

4.  The estimated savings/yr are in excess of $100K

 
Problem Solved!

Here’s what the building component manufacturer has to say:


“The entire staff at Van Technologies genuinely care about the performance of their coatings.  For them it’s about making your finishing system work, not about selling commodity product.”


J. S., Executive

 
Problem Solved!

Here’s what the architectural molding and millwork manufacturer has to say:


“We purchased a new line and needed coatings that would work with the configuration.  We had several different suppliers visit to test their coatings.  However, Van Technologies’ GreenLight Coatings™ was the best overall finish.  It was the most smooth of any of the UV curable coatings.  We continue to use their UV that comes in a variety of different sheen levels. Van Tech has a wide variety of tints that are easy to use.  This was the initial benefit that drew us to try Van Tech’s water base stain system.  Once we started using it, the ease of use was excellent.  All of their water base coatings are very easy to use and versatile over a number of different applications.  We were also able to get a user-friendly Fire Rated coating that we use regularly. Even though we are nearly 2000 miles apart we have excellent customer service.  We have an 8 day turnaround on coatings delivery.  Also, advice or any concerns we have we are responded to within hours or a day. We have even utilized Van Tech to do training with the UV curable coatings for safe use of the coating.  We have been using GreenLight Coatings™ with excellent results since 2009.  The market is ever changing with new customer demands of unique finishes that we rely on the team at Van Tech for the best options available. “


K. L., Finishing Supervisor

 
Architectural Molding Case Study Nature of the Problem:

An architectural molding and millwork manufacturer producing veneer wrapped components installed a new UV and waterborne spray finishing line but was experiencing difficulty achieving the finish quality desired. After multiple trials of competitive materials, they contacted Van Technologies for help.

Procedure:

The lineal waterborne finishing line included the following components:

  1. Initial 4 head sanding/denibbing station
  2. Waterborne priming spray booth
  3. Waterborne stain spray booth
  4. Waterborne sealer spray booth
  5. Lateral transfer IR oven
  6. 4 head sanding/denibbing station
  7. Topcoat paint/clear coat spray booth
  8. Lateral transfer IR oven

The lineal UV finishing line included the following components

  1. Initial 4 head sanding/denibbing station
  2. 100% UV curable sealer spray booth
  3. 5 lamp UV cure oven (2 top; 1 bottom; 1 each side)
  4. 4 head sanding/denibbing station
  5. 100% UV curable topcoat spray booth
  6. 5 lamp UV cure oven (2 top; 1 bottom; 1 each side)

Inspection/Packaging/Shipping occurs at end of lines revealing

  1. fisheyes
  2. orange peel
  3. gloss variation
  4. dryness/cure insufficiencies
Resolution:

A full finishing process audit was conducted followed by adaptation of both waterborne and UV curable GreenLight Coatings™ products via proprietary ASAC Technology.  Primer, stains, sealers, and topcoats were provided to the customer specific to their capabilities resulting in fulfillment of all finish criteria.  Flame retardant options were subsequently provided to support market driven opportunities.

Problem Solved!

Here’s what the architectural molding and millwork manufacturer has to say:


“We purchased a new line and needed coatings that would work with the configuration.  We had several different suppliers visit to test their coatings.  However, Van Technologies’ GreenLight Coatings™ was the best overall finish.  It was the most smooth of any of the UV curable coatings.  We continue to use their UV that comes in a variety of different sheen levels. Van Tech has a wide variety of tints that are easy to use.  This was the initial benefit that drew us to try Van Tech’s water base stain system.  Once we started using it, the ease of use was excellent.  All of their water base coatings are very easy to use and versatile over a number of different applications.  We were also able to get a user-friendly Fire Rated coating that we use regularly. Even though we are nearly 2000 miles apart we have excellent customer service.  We have an 8 day turnaround on coatings delivery.  Also, advice or any concerns we have we are responded to within hours or a day. We have even utilized Van Tech to do training with the UV curable coatings for safe use of the coating.  We have been using GreenLight Coatings™ with excellent results since 2009.  The market is ever changing with new customer demands of unique finishes that we rely on the team at Van Tech for the best options available. “


K. L., Finishing Supervisor

 
Flooring Components Case Study Nature of the Problem:

A manufacturer of hardwood flooring and stair treads installed a UV flatline roll coat filler and stain system followed by a UV spray sealer and topcoat system. After multiple attempts to seek assistance in custom finish system design to accommodate a wide variety of components, they contacted Van Technologies and found the help they needed.

Procedure:

There were a number of flooring components that the manufacturer needed to finish effectively to deliver high quality and maximum wear resistance.  Included were a variety of hardwood floor species configured to all standard linear widths and accompanying stair treads with assembled lip or drop edges and risers.  The flooring would easily be supported by standard flatline finishing methods but the stair treads were 3D and required spray application methods.

With the guidance of Van Technologies and their ability to network with process equipment providers, a system was integrated to provide an exact fit for the manufacturers need for all components.  Included were:

  1. Initial sanding/denibbing station
  2. UV roll coat filling station
  3. Roll coat waterborne stain station with subsequent wiping brushes
  4. UV cure oven
  5. UV spray sealer via Dubois Mist Coater with UV oven
  6. 4 head sanding/denibbing station
  7. UV spray topcoat via Dubois Mist Coater with UV oven
Resolution:

The resulting finishing line exhibits versatility to effectively finish the variety of flooring components manufactured from flat to 3D in dimension.  Further, Van Technologies, using their proprietary ASAC Technology, engineered the appropriate GreenLight Coatings™ products to deliver a remarkable finish that conforms to exceptional wear resistance properties.

 
Problem Solved!

Here’s what the flooring components manufacturer has to say:


“Working with Greenlight Coatings™ has been an essential element in our company’s success. Previous finish suppliers could not contribute the amount of support and knowledge we continue to receive from Greenlight Coatings™ to improve our quality and productivity. Formerly, we had worked with a few different major finish suppliers but the products from Greenlight Coatings™ have an undeniably superior performance. Not only were they courteous in providing hands on support during testing and transitional phases of new products, but they also take pride in maintaining a friendly rapport with individualized customer service.”


K. S., Managing Partner