2006 North American Coil Coating Market Survey

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Marlene Small
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1 I. PLANT IDENTITY: A. Name of Company: B. Plant Location: Smallville, KS D. General Phone #: 2006 North American Coil Coating Market Survey C. Coil Coating Line Designation: Toll Coil Coater Market Survey Questionnaire with Sponsor Highlights Ext. Project #364 Survey # 500 II. COMMENT: This plant has one coating line that processes carbon steel, galvanized steel, aluminum and stainless steel. The products are used in the automotive, truck trailer, containers, building materials, and signage. II. CONTACTS 1. Name: John Doe Date: 1 /25/2006 Title: Manager Address: 100 Main Street City: Smalleville State: KS Zip: Phone: Ext: Fax: Page 1 of 13

2 IV. CHARACTERIZING THE COIL COATING FACILITY A. This plant is an: Steel Production Plant Commercial Coil Coating (Not Tolling) Fabricator / Manufacturer with captive Coil coating Other, specify: Aluminum Production Plant Toll Processor Coil Coater B. Describe the Coil Coating lines at this location using the following table: 1. Widths (inches): < >72 2. Speeds (fpm): < > Capacities (tpy): a. Steel: <50, <100, <150,000 >150,000 b. Aluminum: <10, < 25, < 40,000 40, Indicate Age of: (1) Oldest Line: 1961 (2) Newest Line: Type of Coil Coating: Vertical Horizontal X S-rap 6. Wet: X Dry: Other, specify: 7. Comment: C. Production of this coil coating operation: 1. Rated capacity: 100 K tons / year 2. Project Production : 100 K tons / year 3. Type of Substrate Coated as Percent of Total: a. Carbon Steel: % 5 b. Galvanized Steel: % 60 c. Aluminum: % 30 d. Other, specify: Stainless Steel (1) % 5 4. Average Number of Product/Coating changes per day of production: Share of Production that is toll processing: % Line Operating Hours per year: 8600 Hours 7. Comment: D. Identify major end-use markets for coated product: (distribute % of total) 1. Automotive: % Truck trailer: % Container: % Appliance: % 5. Signage: % Furniture: % 7. Building Materials: 8. Other: % 40 % (roofing & panels) Specify: ( Shelving, HVAC, Metal Doors, Light Fixtures, Aluminum Rainware) E. Comment: Page 2 of 13

3 V. THE FUNDAMENTAL PRIORITY What are the current fundamental priorities related to coil coating: (Distribute 10 points as an indication of priority among the following) 4 Improve Productivity Reduce Operating Costs 3 Increase Yield Improve Equipment Reliability 3 Improve Quality (Surface) Improve Quality (Gauge Performance) Other, specify: VI. ASSESSING THE ADEQUACY OF THE EXISTING COIL COATING EQUIPMENT A. Are your existing coil coating lines at this plant adequate for your needs Yes 1. If No, how would you characterize these needs: Yes * Coating Machinery Increasing Production? Improve Productivity? Improve Quality? Application Engineering Process Flexibility? Field Service? Replacement Parts? If other, specify: * Indicate "x" here if this need is specific to Coil Coating Machinery. 2. If YES, do you anticipate possible future coil coating needs? Yes a. If yes or maybe, comment: Oven improvement in 2006/2007 B. Is the present level of coil coating line automation adequate for your needs? Yes C. How would you characterize your current coil coating line maintenance program? Very Good Good Adequate, or Inadequate D. Comment: Page 3 of 13

4 VII. COIL COATING EQUIPMENT SUPPLIERS COMPETITIVE ANALYSIS A. What factors are most important when you evaluate coil coating line equipment? (Indicate 2 or 3) Low maintenance Speed; productivity Reliability; durability Coating accuracy; uniformity Versatility; flexibility Operating simplicity Technology Other, specify: B. What 2 or 3 factors are most important when selecting an equipment supplier? Availability of application assistanc Builder reputation; experience Availability of parts and service Process know-how Technology Other, specify: C. Who are the leading builders of coil coating machinery? 1. Fata Hunter Price Proven performance Single-source capability D. Rate the above suppliers with regard to the performance factors: (on a scale of 0-10) Supplier Factor 1. Capabilities/interest in engineering the best application 2. Reliability, durability 3. Process knowledge, experience 4. Simplicity; ease of operation 5. Company size, strength, reputation 6. Low maintenance 7. Coating accuracy, uniformity 8. Installation, startup assistance 9. Environmental-related 10. After sales assistance, service Supplier E. What action would you recommend to a builder of coil coating machinery who wants to serve you and your company most effectively? Proven performace and good price F. Comments: Page 4 of 13

5 VIII. CHARACTERIZING COIL COATINGS USED A. Coil Coating Competitive Analysis 1. Identify leading coating suppliers & rate their performance (2)-(5) on a scale of Is the share of your requirements as met by these major suppliers expected to change? No a. If Yes, it will b. Why? Suppliers: gal or dol (1) Annual Volume (gal) Increase Decrease (2) Technical Innovation (3) Service (4) Quality (5) Meeting Market need BASF 50, Akzo Nobel 100, PPG 50, Valspar 300, (6) % Share Annual ($$) B. Coating Technology Trends 0. Characterize the types of coatings now used: Type of Coating Top Coat Material Annual Technologies Volume (Gal.) Share of Total Top Coat (%) Projected Change * PVDFs 250, D Top Coats SMPs 50, I PVC Plastisols Polyesters 100, I Other Acrylics 40, Other Adhesive 60, Other Primer XXXXXXXXX XXXXX XXXXX Backer XXXXXXXXX XXXXX XXXXX Indicate: * S - Will start using I Will increase use of D- Will decline in use E Will eliminate use 1. How do you see coil coating technology changing over the next 5 years (in terms of the use of acrylics, polyesters, siliconized polyesters, PVC plastisols, fluoropolymers PVDFs, SMPs, etc. Will one technology decline in favor of another? We see the SMPs and polyesters increasing at the expense of the PVDFs. 2. Do you think you will be affected by Cool Roof Regulations? a. When will these regulations affect what you order? year (s ) b. The affect will be: C. Chrome Free Treatments 1. What impact will Cr (VI) legislation have on your business in terms of a greater use of Cr-free primer technology, timing? We are using paint containing no CR(VI). Page 5 of 13

6 a. When will this legislation affect what you do? 0 year (s ) b. What are the critical performance criteria (otherwise attributed to Cr containing primers) that need to be satisfied by Cr substitutes? 2. Are you interested in switching to a chrome free primer/pretreatment system? a. If yes, what is more important in selecting a chrome free system? b. Is there any benefit in having a chrome free primer if the pretreatment contains chrome D. What is the relative cost of various coating weights, using 10,000 Lbs. as the base and assuming all other things equal except the run size. Coil Weight (lbs.) 10,000 Relative Cost Per Lb ,000 40,000 80,000 a. b. c. same same same E. Inventory & Unused Paint 1. Typical inventory value of paint? $ 900, How much good quality unused paint do you typically dispose of, run as backer or give/sell back to suppliers for rework? 0 Gallons per year and $ 0 per year (net $ value as purchased) F. Opportunities for new or better Coating Products 1. Is there a performance requirement that is not being met by a coating? No 2. What is the most significant business opportunity you have that an improved coating can help you capture? DK G. Comments: 1. Comment: 2. Comment: Page 6 of 13

7 IX. QUALITY RELATED ISSUES A. What are your 3 most important quality issues? 1. Appearance (dirt ) B. Does your present coil coating equipment (ovens, applicator systems, etc.) prevent you from improving quality or productivity? No 1. Comment: C. Do you monitor your incoming sheet to confirm that it meets specific mechanical criteria (tensile strength, hardness, etc.)? No D. To what physical and performance parameters and properties is your final product guaranteed, what are the guaranteed tolerances, how are properties measured and by whom? (If variable, consider for most demanding product.) 1. Comment: Parameters Yes/ No Guaranteed Tolerances Lab Measuring Method* Measured by Whom** + - a. Coating Weight/Thickness Yes D I b. Tensile Strength No c. Hardness No d. Coating Adhesion during bending Yes D I Parameter: Other, Specify: * D: destructive, ND: non-destructive E - Eddy Current O-other, specify: ** I- internal lab, O - outside lab, C Customer O- Other, specify: E. How frequently do your customers require samples be taken to prove those physical properties? 1 per coil each batch of coils never other, specify: F. Scrap rate attributed to coating-related issues: 1.5 % G. Rework rate attributed to coating-related issues: 0.5 % H. When reject, reclassification or redesignation of finished coils is required, would you say the occurrence is primarily due to: 1. Physical Damage % 0.5 of production? 2. Coating Characteristics/Failure % 0.5 of production? Page 7 of 13

8 I. What are the three most important improvements that you could make to the coil coating line equipment in order to enhance the quality of material coming off the coil coating line? 1. Upgrade ovens J. Comment: Page 8 of 13

9 X. THE USE OF GAUGE & OTHER MEASUREMENT INSTRUMENTATION A. What manufacture (or type) of substrate on-line thickness measurement equipment is used on your coil coating line? None 1. How long have you had these instruments? 2. What is your expected lifetime? years 3. How much longer do you expect it to last? years B. Primer & Paint Thickness Gauging 1. Do you currently use gauging to measure primer or paint thickness? Yes a. If Yes, is it on-line? No (1). What manufacture (or type) of coating thickness (or weight per unit area) on-line measurement equipment is used on your coil coating line? (2). How long have you had these instruments? (3). What is your expected lifetime? years (4). How much longer do you expect it to last years (5). How would you rate the adequacy of your current gauging equipment b. If you do not currently use gauging to measure primer or paint thickness, why not? Off line testing works OK (1). If a technology existed to reliably measure primer or paint thickness, would you be Yes (a) If yes, what priority would you give this investment relative to other investments in improvements you can make on the coil coating line? Highest (b) What would the measurement accuracy need to be to make the investment attractive? + %, 1 - % 1 (.001 inches = 25 microns) c. On how many of your coil coating lines would you be interested in employing on-line gauging to measure primer or paint thickness? (1). Which lines 1 d. If a reliable primer or paint thickness gauge measurement could be utilized, would closed loop control be beneficial to minimize paint usage? Yes 2. What other on-line non-contact instruments do you have on your line? Width gauge Pyrometer Surface inspection Other, specify: None 3. Do you have any problems, concerns or issues with your coil coating operation? No If YES, a. Describe the problem: Page 9 of 13

10 4. Do you plan to make any modifications or improvements to address these issues or modify gauging or process automation on this line? Yes a. What are your primary objectives of these changes in the next 2 years? increasing production reducing operating cost reducing downtime improving product quality reducing emissions b. What is the schedule for implementation? c. What could hinder implementation of these improvements? d. Who is (are) the key decision maker(s) for implementing the improvements? a. Name: John Doe Title: Purchasing b. Name: Jane Smith Title: Plant Engineers 5. Comment: Page 10 of 13

11 XI. HEATING A. Is heating included in your coil coating process? Yes If Yes What type of heating do you currently use in your coil coating process Gas Fired Induction Radiant IR UV Other, specify: 2. Are you currently dissatisfied in any way with the heating portion of your coil coating process? No If YES, is your dissatisfaction with the method of heating employed in the coil coating a. Any limitations that method of heating imposes on Productivity of the coil coating line? b. Any limitations that method of heating imposes on the Quality of the coil coating? c. Maintenance costs related to that method of heating? d. The effect that method of heating has on the cost per ton of the process? 3. Would you consider spending capital funds to improve the efficiency and/or functionality of the heating portion of your coil coating process to address the above? a. What is the likelihood that you would spend capital funds to improve the heating process of your existing coil coating line in the next two years? (Scale of 0-10): 4. Comment: Page 11 of 13

12 XII. PLANS TO ADD OR UPGRADE COIL COATING EQUIPMENT A. Are there any plans or considerations to replace, install new, or upgrade any Coil Coating or related lines at this facility in the next 2-3 years? Yes 1. If YES, describe plans in table below: Type* N-New, or Scope** P (planned) Approx. Is Money Year of U-Upgrade C -(considered) Value. Allocated Order Yes / No 62" Upgrade O Planned 3,000, Yes 2006/07 ** U: Uncoiler ; Sh: Shear; S/S: Stitch & Shear; A: Accumulator; CC: Chemical Coater PC: Prime Coater; FC: Finish Coater; Q: Quench; L/E: Laminator/Embosser; D: Dryer O: Oven; R: Recoiler; W: Waxer; AT: Automation; CL: Coil Car DH-Dual Head Coating Other specify: 2. Approximately how much do you intend to investment in coil coating machinery over the next 3 years? $ 3,000,000 B. Reason(s) for above investment(s): Need expanded capacity at existing facility Need to upgrade or replace outdated equipment Need faster line speed; higher productivity Need greater coating accuracy, uniformity, or better quality, in general Other C. What is the typical lead time between when you initially issue an RFQ for coil coating line equipment and the time you actually issue a purchase order? 6 Mos Yrs D. ROI requirements: E. How many people in your company normally are involved with the evaluation, selection and purchasing decisions for coil coater equipment? 3-4 F. What are the names and title (or function) of the key persons involved in those decisions a. Name: John Doe Title: Purchasing b. Name: Jane Smith Title: Plant Engineere G. Para. XII Comment: Page 12 of 13

13 XIII. COIL COATING INDUSTRY OUTLOOK IN GENERAL A. Looking ahead 3 to 5 years, how do you anticipate industry s need for coil coating (not just the need of your own company) will compare with today, overall? X Increase; expect greater need for coil coating Decrease; expect less need for coil coating Level; expect need to remain about the same Don t know 1. Why? Conversion from post paint to pre-paint. B. What change in the use of coil coatings is expected in specific end-use markets? End-Use Markets Construction Appliance Containers Transportation Increase or Decrease Increase Increase Increase % Change XIV. CONSULTANT PROSPECTS A. Would you be interested in the services of an individual experienced with coil coating equipment for the application of paints and chemicals, including phosphate, chromate and acrylic coatings that can help you improve your existing production or help get new equipment into production. No B. If Yes, For what? 1. Coil coating production planning Paint lines / Galv line 2. Coil coating technology development and implementatio 3. Coil coating equipment and process evaluatio 4. Coil coater operation evaluation and trainin 5. Productivity and Quality improvemen 6. Installation and startup supervisio 7. Project management Page 13 of 13

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