The existing method of activating the thermal transfer in a gas-fired convection heat tunnel did not consistently make a complete transfer of the characters to the keyboards.
Excessive Scrap
The incomplete transfer of the characters to the keyboards resulted in an excessive number of keyboards being scrapped.
Slow Line Speed
The existing line speed of 15 feet (4.6 meters) did not produce enough finished keyboards to satisfy customer demands.
Solution
Heat
Two Model 4554-A-25-12 High Density Pyropanels were used to provide a precise amount of heat to the thermal transfer.
Instant On/Off
The High Density Pyropanels heated up and cooled down instantly in response to keyboard placement on the line.
Benefits
Improved Quality
he precise heat provided by the High Density Pyropanels consistently made a complete transfer of the characters to the keyboards.
Reduced Scrap
The consistent transfer of the characters to the keyboards virtually eliminated the need for the manufacturer to scrap keyboards due to poor character quality.
Increased Line Speed
The manufacturer increased line speed by 133% to 35 feet (10.7 meters) per minute and was able to produce enough finished keyboards to satisfy customer demands.
Energy Savings
The ability of the High Density Pyropanels to heat up and cool down instantly enabled the manufacturer to operate them at 5% power when keyboards were not present on the line, reducing the amount of energy consumed by the activating process.
