Scott Sutcliffe, Owner of Formcrete Fiberglass in Oklahoma, emailed us:
Here’s your pat on the back!
We spray resin from the gun before scanning to wet out gel coat before chopping, to ever so slightly spray a little resin on top of the laminate for, let’s say an embedded feature such as a foam structural rib, structural features we’re simply hand laminating and wetting out or to slightly additionally wet out over an area that is highly detailed and tough to roll out.
All of the immediate above is really hard to nail down/quantify as to just how much this affects our overall consumed resin above and beyond what is being chop sprayed.
Therefore, I consider a 2-3% overall variation in resin consumption to be great.
Every month end, we meticulously physically record our resin and gun roving consumption.
Year to date, every month our gun operators are hitting exactly a 39% fiberglass content in production.
We could not be doing this without you guys and your TFM equipment!
Terry, Owner of Fiberglass Specialties in Minot, ND, after years of using TFM Monitors, wrote to us recently:
Just thought I’d drop you a line to say thanks again for the great equipment and service. Kevin and Dave were here to install two mor TFM’s on our new portable choppers. Instant success and savings on material, but more important, I think is the consistency of each part.
Our products vary in size and weight from 30 pounds to 6000 pounds. Whether it’s consistency or savings it’ still a “no-brainer” to Have TFM’s. For those who do not have your equipment they are seriously missing the boat.
C.F.A., Composites Fabricators Association’s Technical Director, Bob Lacovara, wrote to us:
I would like to thank you for the use of your Materials Monitoring System during the course of the CFA Emissions Test Project. As you know we were working with a very sophisticated data collection system in the Dow Chemical Applications Lab. In addition to working in an ISO 9000 enviroment, we had very stringent quality assurance requirements for all aspects of the test project.
I was very pleasantly surprised to take note that your Monitoring System was accurate to within 0.1 lb during the application of 35 lbs of chopped laminate. This was based on operating the TFM production unit in conjunction with expensive, high sensitivity lab equipment. In addition to being accurate to well within the requirements of a production setting, the capability to calibrate the unit for resins of various densities was very useful.
When using controlled spray application, monitoring material flow is critically important for the operator to be able to pace material distribution across the mold. Your monitoring equipment should allow fabricators to control the molding process very accurately.
Thanks again for the use of the equipment during the CFA Emissions Test Project.
The general line among our customers is that our equipment pays for itself within 3 to 6 months!
One of our customers purchased 16 units, about a $96,000 investment. The first year using TFM Monitoring equipment, they saved over $300,000!
Thomas Boehmer wrote us from Kitco, Inc
I am writing to let you know how pleased my staff and I are with our recent purchase of one of your monitoring systems. I am embarrassed to say that I looked at your system about 10 years ago and with the product we were making at the time it did not warrant an expense of this amount, (I thought). Boy was I wrong!
We are now producing some larger parts that weigh approximately 150 pounds each and a quantity of 6 a day and soon to be 8 per day. I remembered talking to you about 10 years ago and thought what a perfect part to use TFM monitoring equipment on and now we can use it on some other stuff also. If it helps us out on some smaller parts then we will just get more bangs for our buck. I thought this unit was just going to be used to monitor resin, glass percentage and the total part weight, but after the first day I realized this is the best training money we ever spent.
After we got the unit dialed in and set it up with the parameters for the parts, we started to increase our glass to resin ratio. We were running around 33 – 35% but sometimes hit lows in the high 20’s, which caused a few problems. We are pleased to be at a consistent 41% and have hit as high as 43% a few times. What a blessing to see these numbers at a time when resin prices seem to be constantly on the rise.
After the first week of use and reducing the excessive weight in parts, increased glass content, we saved $1,000 on our resin bill. Wow, we are amazed and impressed. As I said earlier, the smaller parts that were no big deal, has turned out to be a bigger savings than the big parts. The smaller parts are run on a less consistent basis, my chopper operators had a hard time remembering the desired weights of the parts.
And for training, it is an excellent tool. Our standard training before consisted of the mil gauge and checking everywhere on the part. Now after doing the mil gauge on the first few parts when setting up the equipment, they just look at the monitor and read the total weight to dial in the part. A new chopper after 4 hours of chopping made parts that looked like I chopped with my 23 years of experience.
We already ordered another unit for the gel-coat system for the large parts and will be ordering another chopper and gel-coat unit for another production line getting ready to start. This will allow us to start saving money and making more consistent parts for our customers.
Once again, a million THANKS for the fantastic product.