- IntelliFlow Case Study 03-512-01 EN [ English ]
Thyssenkrupp
Bilstein
Binks System Solutions Bring� Performance and
Efficiency� to the Bilstein Products Paint Line
CHALLENGE
Thyssenkrupp Bilstein of America,
Inc. paints high-end ride control
products at their Hamilton, Ohio
facility. When it became necessary
to replace an existing competitor’s
product due to insufficient
performance, Jason Meredith, an
advanced coatings engineer at the
company, relied on his previous
experience with Binks solutions. His
coating line needed to handle low
flow rates for a waterborne coating
applied electrostatically with three
component metering, and the
application needed precision flow
control down to 4ccs of water-based
material.
SOLUTION
Keeping in mind the tight tolerances
the system needed, Meredith worked
with the company’s local distributor,
Billy Meyer, systems sales engineer �at
American Industrial (an OTC Industrial
Technologies company), to assist in
finding a solution. Lab trials were set
up at the Toledo lab facility to demo
the IntelliFlow RF2 meter and mixing
solution. Meredith liked the touchscreen
control panel that makes operating the
machine simple and allows flexibility for
adjustments, and collects, records and
downloads process data in real-time.
Another feature of the IntelliFlow unit is
constantly flowing resin, catalyst and
water, instead of dosing a little at a
time, all while being monitored on the
control screen.
The IntelliFlow offers many benefits
but a surprising one was that color
change times were cut in half. Prior to
integrating the new system, Meredith
says it �was necessary to flush all
three channels of the system, which
would take 20 minutes. The IntelliFlow
unit flushes only the resin channel so
effectively, �it saves time and money,
while increasing uptime. Meredith
says they were able to reduce color
change time to 9 minutes or so.
Thyssenkrupp Bilstein had struggles
and set out to identify areas to
reduce costs and material waste
while increasing production on their
paint line. A system upgrade with
the Binks IntelliFlow RF2 delivered
remarkable results.
Important Phrase
From Article Process control is key – that’s
why the IntelliFlow� is so important.
The unit’s repeatability, true-ratio
control, operator interface and
data collection capabilities are
unmatched. The unit has allowed
a true reduction in flow rates
which provides real-time cost
savings, explains Meyer.
Anybody can sell equipment.
People make the difference. The
level of customer service we’ve
received from American Industrial
over the years is great, and the
support from Binks has also been
great. It’s nice to know support is
just� a phone call away.
RESULT
A significant driver for installing
the IntelliFlow meter and mix
system was Bilstein’s conveyor
system upgrade to a shorter
omega loop that allowed
the parts to get closer to the
applicator, increasing efficiency
and lowering flow rates below
the previous systems capabilities.
The success of the IntelliFlow mix
and meter system allowed for a
transition from 3/8 ID tubing to ¼
ID tubing, resulting in substantial
material waste savings. End result
from this one upgrade: High
quality output, less waste, and
more production.
Jason Meredith, �
Thyssenkrupp Bilstein
Thyssenkrupp Bilstein collaborated with
the local distributor, American Industrial,
part of OTC Industrial Technologies, to
find a solution.
A powerful solution can start with a simple conversation
We want to help build the best solution to your application challenges. Learn more about what
we can offer by reaching out to the office nearest you.
For more information,
visit binks.com. ©2025 Binks.
Models and specifications subject to
change without notice. All rights reserved.
Form No. 03-512-01
Americas 1.800.992.4657 marketing@binks.com
EMEA 44.0.120 257.1111 marketing-eu@binks.com
China 86.21.33730108 mkt_cn@binks.com
Japan Sales Office 81.45.785.6421 jp-rans-tokyosales@binks.com
Japan Binks/DeV 81.45.785.6421 jp-binks-devi@binks.com
India/SE Asia 44.0.120 257.1111 marketing-roa@binks.com
SYSTEM PRODUCTS USED:
• IntelliFlow RF2 Electronic Proportioner
• Aerobell 168 Rotary Atomizer
• TurboDisk Rotary Atomizer
BENEFIT
Thanks to the investment in new
Binks solutions and applications
changes, Bilstein is achieving
�99.8% first time quality off the
paint line, according to Meredith.
Additionally, color change time
has been reduced from 20
minutes to below 10 minutes.
That could be an extra 30
minutes or more of production
per shift.
After installing the new Binks
system, featuring the IntelliFlow,
Bilstein’s paint process
has become so efficient
that other Thyssenkrupp
Bilstein facilities are
looking at the Hamilton
plant’s results to guide
their own cost savings
and material consumption
reduction efforts.
