Powder Coating Applications
As the coatings industry changes from solvent based coatings to newer, more durable and ecologically friendly powder coatings, the role of infrared heat becomes more pronounced.

Curing solutions that were once obtainable using a single curing source are no longer the best when dealing with powders. The use of a convection only cure system will have many disadvantages:

• Uses more energy for heat up, curing and cool down
• Requires longer curing times, slower line speed
• Much larger footprint in your facility
• Unresponsive to the flexibility needed to adjust heat zones for reduced energy consumption and processing different parts
• Convection air movement and by-products can create contaminates on coated parts.

By implementing an electric infrared booster oven prior to final curing, the surface can be flashed off quickly, initiating the gel (polymerization) of the powder. This will reduce inconsistencies in color, contamination and keep powder from being blown off of the part.

There are hundreds of powder formulations in use today. Film thicknesses range from under 1 mil to over 15 mil and the range of colors, gloss and applications is equally as vast. What these diverse powder formulations do have in common, is near-perfect compatibility with infrared radiation as a method of curing.

New technologies are continually improving finish chemistry. Precise, reproducible oven temperature control characteristics are needed to assure the potential of today’s' new powder formulas are met. This is the custom control you get with electric infrared curing systems.

High Density Board
Fostoria has designed infrared modular sections that incorporate a custom hi-density refractory board, composed of aluminum silicate and other non-organic binders. These reflector boards are especially useful in higher watt density applications such as for curing powder coatings, and are self-cleaning in many operations.

High-density boards are capable of withstanding up to 100 watts per square inch and act also as a generator of medium wavelength infrared.

This greatly benefits the powder finishing and curing process. As the coating continues to cure, it in turn heats the product being coated, aiding in the acceleration of the curing process.

A wash cycle always precedes the application of a coating, and removal of residual water is essential before coatings are applied. A Fostoria oven rapidly brings parts to 225 degrees F (or higher if desired), and evaporates all moisture. Fostoria ovens can also combine drying and preheating cycles into a single process when necessary, giving manufacturers the option of a complete powder cure system using only electric infrared. This greatly reduces the system footprint and cost.

Liquid Finishes
Infrared provides the heat, the cure, the bond, and the catalyst for a wide variety of industrial processes. Its most important role, however, is one in which it first found widespread use: the curing of liquid coatings.

Whether solvent-based, waterborne or non-reduced, infrared is the curing technology of choice among manufacturers of metal, plastic, and composite parts.

Fostoria Industries is an acknowledged leader in the design and development of high-efficiency infrared ovens for finish curing. We were the first to demonstrate infrared’s effectiveness in high speed production curing, the first to introduce energy-saving zone control, and the first with virtually every development now regarded as standard in our industry.

Today, what distinguishes Fostoria is our ability to engineer systems with the power and wavelength, as well as the flexibility and control, to complement specific coatings systems. Where there is flexibility in the selection of a coating, Fostoria can also prepare recommendations and documentation for a finish and curing combination that best matches the application.

Most ferrous, and virtually all non-ferrous metal surfaces and composites that are coated with paint, can be cured using electric infrared systems. The ability to precisely control and zone infrared heat provides advantages over other curing methods. Additionally, infrared penetrates the coating and heats from the substrate out, preventing blisters that can result from trapped solvents.

Automotive & OEM Applications
Paints & Finishes, Plastics, Glass, Fabrics & Adhesives

Interior Trim & Seating
Fostoria has designed and manufactured OEM curing systems for use world wide. Just a few of our repeat customers are: GM, Boeing, Lear and Ford. We’ve handled many different materials for everything from window glass to headliners to varied interior parts and components. Our experience doesn’t stop with just ovens. OEMs have also asked us to supply material handling systems.

Fostoria infrared ovens are designed to process seating components for relaxing fabric, removing moisture and de-wrinkling vinyl, cloth and leather for seat fabrication; drying coatings on plastic parts, and packaging finished parts for shipping. Infrared is also the process of choice for interior parts ranging from seatbelts to carpet.

Shuttle Ovens
Infrared shuttle ovens condition vinyl in a fraction of the time required by air systems. Often purchased to improve productivity, they simplify handling by "shuttling" a warm sheet out with each cold sheet put in. The ovens feature continous feed sensors to assure uniform temperatures, and a uniform result. Advanced oven modules incorporate an exclusive pneumatic "trap" to clamp the vinyl on four sides, thus preventing dimensional changes prior to forming. Common applications for shuttle ovens include: door panels, dashboards, steering wheel coverings and arm rests. Manufacturers of air bag compartments use these ovens for pre-heating vinyl prior to vacuum forming.

Storage Ovens
Re-engineered assembly systems for increased productivity have intensified the need for storage ovens, which heat parts such as wire harnesses, making them easier to assemble. These ovens are also used where pressure-sensitive adhesives perform more efficiently at higher temperatures (such as with body side moldings) and where pliability aids fit (such as with rubber bushings applied to door fittings).

We offer both infrared and convection storage ovens. We welcome the opportunity to consult with you regarding these applications, and to offer some case histories where the use of such systems has eliminated adhesive peel-off, reduced rework and eliminated related warranty claims.

Conveyor Ovens
Conveyorized Fostoria ovens are used for a wide variety of glass performance and decorative effects. Systems are available for tempering and annealing and for pre-heating and tacking for lamination. Fostoria engineers specialty ovens to cure inks, ceramic paste and reflective coatings used on head and tail lights. Pre-heated vinyl sheets are used in the lamination of safety glass, without heating the glass. Paint on glass applications, including windshield "perimeter black-out" are common uses for our electric infrared ovens.

Total Systems and Specialty Systems -
Inks
Fostoria Infrared Systems provide high-speed drying of printing inks. Systems are infinitely adjustable, so pressmen can fine-tune drying cycles to accommodate the specific stock, coverage, pile temperature, and ink formula. Advanced cooling technology is provided through Fostoria’s exclusive reflector/heat-sink design. When combined with high-velocity/high-pressure blowers, the result is the highest degree of control and repeatability.

Curing Plus Material Handling
Fully integrated systems can be engineered for applications in the automotive, electronics, appliance, and aerospace industries. They are also applicable to the manufacture of a wide variety of building products, from window grilles to press-formed panels made from log shavings.

For example, Fostoria offers a turnkey system for curing, cutting, and handling the "honeycomb" kraft paper used as a core material in garage doors, man doors, and office dividers. The system allows the manufacturer to purchase the honeycomb material in its unexpanded state and, using the Fostoria system, expand the product to the desired length, width, and cell size. The sequence of operation features:

• Expanding the honeycomb to the correct cell size by applying the proper tension to the product as it is conveyed.
• Setting the honeycomb to its expanded size by activating the heat-sensitive resins in the paper. Fostoria’s Transco ovens provide the perfect solution to this step of the process.
• Cutting the panels to the exact width and length. The cuts in both directions are made while the web of honeycomb continues to move on the conveyor system.
• Curing the adhesive after application by a roll coater and prior to the exterior panels being attached.

The extension and adhesive curing of honeycomb is but one of many turnkey system approaches Fostoria’s application and design engineers can provide to solve complex process and material handling problems. We can provide the benefit of total system responsibility through our expertise in both process heating and material handling.

Electric Infrared Heat Sources
Electricity is the energy of choice for many industrial infrared applications. There are many reasons for its popularity, such as: installation cost, controllability, ability to produce high temperatures quickly, and it is a clean form of heat.

Electric infrared emitters provide flexibility in producing the desired wavelength for a particular application. Fostoria offers a wide selection of electric infrared heat sources to meet the various requirements of industrial applications. Each of the different types of heat sources has particular characteristics which determine the suitability of the heat source for a particular application.

For most applications, it is sufficient to know that short wavelength, tungsten filament sources (quartz lamps and G-30 bulbs) provide high radiant efficiency, deep penetration and a fast rate of response. Medium and longer wavelength nickel chrome filament sources (quartz tubes and metal rods) are less radiant efficient, but are more rugged, less expensive, and in some cases provide the best wave length for the application.