Category Archives: Case Studies

One-On-One Attention Helps International Marble Excel

One-On-One Attention Helps International Marble Excel

The Challenge
International Marble Industries was experiencing air entrapment in the gel coats it used for its line of cultured marble products. Previous suppliers were unable to correct the problem. Air entrapment causes pitting and other cosmetic flaws in the finished surface.

The Answer
HK Research worked one-on-one with International Marble to develop a gel coat specific to its needs. With input from International Marble, the 1404 Series of Low-HAP NPG-ISO gel coats was born.

The Outcome
International Marble Industries no longer deals with air entrapment, and easily made the transition to HK’s low-HAP gel coats. Today, the two companies continue working together developing new products.

“We feel HK Research is the best at what they do, and that makes us even better at what we do. They have an excellent technical support team, and I appreciate the fact that Dick Higgins is only a phone call away.”

– Nathan Rivera, Operations Manager, International Marble Industries

www.internationalmarbleindustries.com

 

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Better Quality + Increased Production = Lower Emissions for Jacobs Manufacturing

Better Quality + Increased Production = Lower Emissions

The Challenge
Jacobs Manufacturing was facing two major problems with its gel coats. First, the pump houses and other fiberglass enclosures the company produces were simply not holding up to the typical 100% sun exposure they experience. There was chalking and fading, in most cases, within six months. Second, the lack of a usable low-HAP gel coat was putting pressure to limit emissions on other areas of production.

The Answer
Jacobs began using HK Research’s LHA series of FRP gel coats and noticed the difference immediately. Poor quality, bulky “extender fillers” are the reason gel coats chalk or fade when exposed to the elements. HK Research does not use fillers, therefore delivering a higher quality gel coat. HK is the recognized leader in low-HAPs, offering high quality gel coats with fewer environmentally harmful emissions.

The Outcome
Since switching to HK gel coats there is no visible fading, the exterior retains its luster and chalking is no longer a problem in Jacobs Manufacturing’s products. Additionally, they have been able to increase production by using HK’s low-HAP gel coats.

“In 2002, our production was up 12% over the year before but we actually lowered our emissions. In the last 20 years we have seen tremendous strides in the quality of finishes that are available. Gel coats really hadn’t kept up until HK Research came along.”

– Mike Jacobs, President of Jacobs Manufacturing

www.greencis.net/~jmc

 

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Donzi Marine Finds Gel Coat Answer

Donzi Marine Finds Gel Coat Answer

The Challenge
Gel coat inconsistencies were consuming valuable time during daily production meetings and creating production nightmares for Donzi Marine, a leading manufacturer of high-performance boats. Specifically it was gel coat color variations from one batch to the next, a common problem in boat manufacturing, that was creating headaches for Donzi.

The Answer
A switch to HK Research’s HydroShield® Lite gel coat solved the problem. HK Research holds the tightest color specs in the industry, thanks to a fully-automated plant and a unique method of making gel coats. That kind of barrel-to-barrel consistency means fewer, if any, finish repairs.

The Outcome
For Donzi, it means one less thing to worry about in production meetings.

We used to spend a big portion of our daily production meeting wrestling with gel coat problems. Since we switched to HK Research gel coats, the topic rarely comes up.”

— Steve Simon, VP Operations, Donzi Marine

www.donzimarine.com

Editor’s Note: It is with great sadness that we learned of the untimely death of Steve Simon, Team Donzi’s Director of Racing. To view a tribute to his life and work, please click on the following link:
http://www.donzimarine.com/DonziWebsite/Site/simon/stevesimon.html

 

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Post-Cure Cracking Eliminated at Flats Cat Boats

Post-Cure Cracking Eliminated at Flats Cat Boats

The Challenge
The heat and humidity in Texas makes working with gel coats extra tough. Bill Allison of Flats Cat Boats knows the cost all too well. Once he had to rebuild eight boats at his own expense because of post-cure cracking.

The Answer
Several years ago HK Research formulated a custom-made solution that stands up to the difficult environment of Allison’s plant, and his personal expectations.

The Outcome
The change was immediate. The issues with volatility and cracking are long gone, and Allison wouldn’t consider any gel coat supplier other than HK.

“We only use the best products, and HK definitely has the best gel coats. And best of all, they stand behind their products 100%.”

— Bill Allison, Flat’s Cat Boats

www.flatscat.com

 

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Consistency a Must for Diversified Fiberglass Fabricators

Consistency a Must for Diversified Fiberglass Fabricators

The Challenge
As a manufacturer of automobile parts, Diversified Fiberglass Fabricators’ colors have to match vehicle paint jobs perfectly. As Bill Rhew’s business took off, he needed a gel coat provider that could keep up with his growing needs, while providing the kind of color consistency that his customers demand.

The Answer
Working together, Rhew and HK Research have developed a variety of different colored gel coats specially formulated for Diversified Fiberglass Fabricators. HK representatives visit the plant regularly and are available on the spot if there are any problems.

The Outcome
For more than 20 years, HK Research’s special formulation, consistency and superior customer service has helped Diversified Fiberglass Fabricators’ satisfy their demanding customers.

“They are some of the most knowledgeable people that I’ve ever dealt with, and I’ve dealt with a lot of them. HK makes some of the best gel coats I’ve ever used and that’s why I’ve been with them for so long.”

–Bill Rhew, President, Diversified Fiberglass Fabricators

 

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Superior Quality Worth It to Piedmont Well Covers

Superior Quality Worth It to Piedmont Well Covers

The Challenge
Pam Wainscott, owner of Piedmont Well Covers, was familiar with the problems that can arise with poor quality, cheap gel coats. Trash that clogged the spray guns, inconsistent color and other problems that cost time and money. That’s why her company has only dealt with one gel coat supplier during its 10-year history.

The Answer
Wainscott witnessed the quality of HK Research’s gel coats when working with another company and didn’t want to take a chance on using anything but the best. Spending a little more for quality gel coats makes a big difference, not just for Piedmont Well Covers but for the satisfaction of its customers too.

The Outcome
Because HK Research provides unmatched barrel-to-barrel consistency, Piedmont Well Covers never faces production obstacles or slow-downs due to the quality of its gel coats.

“We could go with a cheaper product, but we would not get the excellent service and superior quality that we get with HK. It’s just not worth it to use any other gel coat.”

–Pam Wainscott, Owner, Piedmont Well Covers

 

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Pro-Line Boats Finds Accessible Partner

Pro-Line Boats Finds Accessible Partner

The Challenge
Because FRP products vary from factory to factory due to temperature, humidity, and the smallest of changes, suppliers must be attuned to individual needs. Pro-Line Boats was struggling with the bureaucracy at its supplier, which often took several days in responding to an issue or request.

The Answer
More than two years ago Pro-Line began using HK Research’s tooling and production gel coats. The first time a gel coat issue arose, Pro-Line’s Vice President of Manufacturing John Walker picked up the phone and HK President Dick Higgins was immediately available on the other end.

The Outcome
In addition to excellent customer service response times, Pro-Line Boats experiences better gloss retention and workability thanks to the high quality of HK Research’s gel coats.

“With HK Research I get to talk to the decision-makers and I get immediate results. With other companies, there’s a ton of bureaucracy and it takes several days to get a response.”

— John Walker, VP of Manufacturing, Pro-Line Boats

www.prolineboats.com

 

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Enabling Advancements at Blue Wave Boats

HK Research Enables R&D Advancements at Blue Wave Boats

Boatbuilding is an evolving science. According to Steven Parks at Blue Wave Boats, a leading manufacturer of saltwater family fishing boats, one of the most common terms heard at the company’s production facility is “what if ….”

That simple phrase has helped the Parks family, which includes Steven, his parents Roger and Pam, and his brother, Richard, grow the family-owned business considerably in the past 15 years – from a small 1,500 square foot shop in 1992 to, as of last year, a new 165,000 square foot state-of-the-art production facility in Seminole, Oklahoma.

“One of the reasons we’ve been able to grow so quickly and remain successful is our robust research and development efforts,” Parks explains. “We continually work with our customers and vendors to identify and meet existing and new market’s needs.”

The Parks desired a marine gel coat that provided a rich visual identity for its boats that would help the line stand apart on the showroom floor and endure in the elements. After much research and consideration they selected High Definition™ marine gel coats, an innovative new product from HK Research Corporation, boasting exceptional depth and boldness in a spectrum of high definition colors.

 

Improved Production and Product Quality through Processing Innovation

For years, Blue Wave Boats has relied on HK Research to help the company maintain that quality and technology leadership approach.

“The gel coat is the first thing people see when they look at one of our boats – whether it’s at a dealership or in the water,” Parks says. “We can’t afford for them to experience cracked or faded hulls. HK Research helps us provide our customers with the highest quality, best looking saltwater fishing boats available.”

In conjunction with the new production facility, Blue Wave Boats significantly upgraded equipment. For example, the company now relies on closed mold processes, such as resin transfer molding (RTM), to fabricate many of its smaller components such as lids and consoles, as well as developing some larger components – ensuring more consistent quality and faster, more efficient manufacturing.

“The HK Research gel coats work perfectly in all of our operations – from our traditional hand layup to our newer processes,” Parks says. “In fact, it was our confidence in these products and HK Research that helped us to make the equipment and infrastructure investments we needed when we moved into the new facility.”

 

Redefining Boat Colors through Advanced Gel Coat Solutions

In addition to new capacity and improved production techniques, Blue Wave Boats is also investing in new products. The company recently finished trials and is ready to begin production using the new High Definition™ marine gel coats from HK Research.

“These new products enable better color selection and result in deeper, bolder hues that have changed the way we look at our boats,” Parks explains. “As an example, comparing HK Research’s High Definition™ black gel coats to others we’ve seen in the industry is literally like comparing night and day. Nothing else truly looks black any more. They’re also easier to use and fit well with our new production processes.”

HK Research developed the new High Definition™ gel coats specifically for boat hulls and decks where deep, bold colors are desired. When fabricated properly, components made with these resins will not blush or fade under shrink wrap or below the water line. They also work well with HK’s proprietary CopperCoat™ Patching System, enabling invisible patching following minor damages, and come in wide spectrum of colors. These gel coats are MACT-compliant, enabling styrene emission levels below 30 ppm in operations such as those at Blue Wave Boats.

 

Advancing the Science of Boat Building through Industry Collaboration

The new production facility, added capacity, processes and product implementation are just the most recent examples of how Blue Wave Boats, with help from HK Research, continues to advance boat building science and provide new value to their many customers. After 15 years, apparently no one in the company has forgotten the two words that started it all – “what if ….”

HK Research recently launched a new website,www.hk-marine.com.   The site is dedicated exclusively to premium gel coats designed for the specialized demands of the marine industry.

Based in Hickory, North Carolina, HK Research has the largest fully automated, computer-controlled facility in North America designed exclusively for the manufacture of premium gel coats in the marine and composites industries. The company produces a wide range of products, including NPG-Isophthalic clear and solid gel coats, specialty blends, liquid pigments and others, that offer the performance needed in today’s challenging applications. HK Research also carries the largest line of low-HAP gel coats on the market.

For more information about Blue Wave Boats, visit “http://www.bluewaveboats.com”. To learn more about HK Research, visit www.hk-marine.com or call 1-800-334-5975.

 

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