Installation of the new equipment required the construction
of a new, 50-foot-high building addition to Gateway's existing
facility that could accommodate the vertical components of
the system.
PRODUCTS FINISHING — PFonline.com
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ABD's waterfall application system. Finally, Gema supplied
the powder application equipment, including the vertical-
track spray gun array and automation software to control
paint application. The Gema guns use an electro-magnetic
field to sense the aluminum profiles in order to charge the
powder in real time, ensuring a highly effective and optional
finishing application, Gateway says.
Even the powder paint, supplied by both Sherwin Williams
and PPG, is formulated specifically for the new equipment.
Ziegler says all Gateway extrusions are finished to meet the
American Architectural Manufacturers Association (AAMA)
2604 durability performance criteria, and the higher-
performance standard AAMA 2605 is also attainable with
the new paint line.
Efficiency and Expansion
The line is designed for efficiency as well as environ-
mental sensitivity. Gateway says it includes a powder
reclamation system engineered for high efficiency, and
coating booths equipped with rolling curtains and
engineered vacuum chambers that ensure maximum
powder re-utilization with minimal waste. The paint
line also features a real-time water management system
to regulate pH levels, outflow rate and temperature to ensure
that local environmental requirements are continuously met.
Installation of the new equipment required the construc-
tion of a new, 50-foot-high building addition to Gateway's
existing facility that could accommodate the vertical compo-
nents of the system. Ziegler says removal of the old coating
line equipment and creation of a new shipping area in the
front of the factory also allows for a more effi-
cient flow of materials and products through the
building. He says the company's overall invest-
ment in the new plant and equipment was several
million dollars.
The new vertical line is part of a multi-
phase expansion plan for Gateway. In 2015, it
purchased the 129,000-square foot production
plant it had been leasing in the Union Industrial
Park as well as adjacent properties. The
company also purchased a new 7-inch extrusion
press as an upgrade to existing equipment. Last
year, Gateway expanded capabilities with the
purchase and installation of a second press to
accommodate 9-inch extrusions. Future plans
include construction of new office space,
additional exterior driveways, paved parking
areas and new landscaping.
For information: Gateway Extrusions,
gwextrusions.com; Bulk Chemicals, bulk-
chemicals.us; Gema, gemapowdercoating.
com; Sherwin Williams, oem.sherwin-
williams.com; PPG, ppgtruefinish.com.
All Gateway extrusions are finished to meet
AAMA 2604 durability performance criteria.
EXPANDED POWDER COATING CAPABILITIES