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Solar Products Case Study on Paint and Powder

Solar Products Flat-faced Radiant Panel Heaters
Solar Products, Inc.
228 Wanaque Ave 
Pompton Lakes, NJ 07442


Infrared/Convection Combination Oven conserves floor space and increases line speed for satellite amplifier manufacturer

The customer was originally using a batch oven to cure the powder on the satellite amplifiers. This process had several drawbacks; slow production, poor coating consistency, and inflexible oven design.

After time, it was necessary to upgrade the oven to achieve higher production rates. Several optional oven designs were reviewed; larger batch oven, continuous gas convention oven, continuous medium wave electric infrared oven.

After careful consideration, it was decided that a larger batch oven could obtain the desired production, but had too many other drawbacks (as noted above). The continuous convention oven required more floor space than was available in order to obtain the desired production rate.

The electric infrared oven achieved all of the goals for a new curing oven:

  • faster production
  • minimal floor space
  • reduced maintenance requirements
  • low energy consumption
  • reasonable capital expenditure
  • flexibility for faster production rates in the future, accomplished by sectional oven design


Floor Space
It was estimated that a 40'-50' long convection oven would have been required for this application. The infrared oven length is 10'. Either oven would require a 15' area for loading and unloading the parts.

A gas convection oven would require preventative maintenance several times a year. The infrared oven has been installed for 2.5 years with no requirement for maintenance to date. With a typical life expectancy of 25,000 hrs for solar products panel heaters, the customer will be operating for a long time without any maintenance problems.

Line Speed
A gas convection oven would have required a 20 minute dwell time. The original infrared oven design was based on line speed of 1 fpm and a dwell time of 10 minutes. In actual operation the conveyor speed is 1.5 fmp with an oven dwell time of 5-7 minutes.

Energy Consumption
The input power rating is often viewed as the actual power usage for an electric infrared oven. In this case, the oven had 70kw of electric infrared installed. But, in actual operation, the energy usage is less than 30 kw. The energy cost calculation is 30 kw x 12 cent per kw*hr =3.60 per hour of operation. At 90 parts per hour, that equates to 4 cent per part. The energy consumption for paint and powder applications typically accounts for less than 1% of the product selling price. Our guess is that 4 cent is well below that 1% margin. The best part of Solar Products panel heaters is that there are no external reflectors. External reflectors only get dirty over time, which reduces the heater efficiency. Solar products heaters maintain a consistently high radiant efficiency (80%) over time.


Specifications Details
Part Description Aluminum or magnesium cast parts variable wall thickness
Part type Satellite dish amplifiers for the communications industry
Coating Polyester powder
Coating application Manual electrostatic spray
Length of oven 10' long oven
Zones per oven 2 zones - 9' heated length for both zones
Zone 1
Zone 2
3' long section operating at 900o F
(2) 3' long sections operating at 875o F
Oven type Infrared with air assist
Heater type Solar Products F-Series panel heaters
Input power 70kw for the heaters
Actual power usage Less than 30kw
Conveyor type Overhead monorail
Conveyor speed 1.5 feet per minute
Weight of part 5 lbs max
Production rate 90 parts per hour
Gel and cure time (dwell time) 5 - 7 minutes


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We are a distributor of infrared heaters. Always consult manufacturers installation instructions for proper installation of the products or systems shown on this website. © Copyright 1999-2019 Mor Electric Heating Assoc., Inc.

5880 Alpine Ave. NW - Comstock Park, MI 49321  USA
Tel 616-784-1121 - 800-442-2581 - Fax 616-784-7775

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