Gema OptiFlex Pro C: The professional guide for perfect powder tests and very small production batches
Are you developing new powders, inspecting batches, or coating small, valuable sample parts? The Gema OptiFlex Pro C with its unique fluid application cup is your tailor-made solution. This guide shows you how to optimally use the system for reproducible laboratory results and efficient small-series production.
What makes the OptiFlex Pro C unique
In contrast to the large production models of the series, the Pro C is designed for minimal powder consumption and maximum flexibility. It is the ideal bridge between development and series production.
🎯 Core advantages
- Perfect for very small quantities (from approx. 20 g/min)
- Self-fluidizing application cup (150 ml or 500 ml)
- Fast and clean color/powder changes
- Can be combined with other coating units
⚙️ Typical applications
- Powder development & formulation tests
- Batch inspection and quality control
- Coating of sample and prototype parts
- Small-series production (e.g. special-purpose machinery construction)
From unboxing to the first coating result: your start-up guide
- Check the scope of delivery: In addition to the OptiSelect Pro gun (GM04) and the OptiStar 4.0 control unit (CG21), you will find the application cup (500 ml as standard), base with filter, all pneumatic hoses, and the operating manual.
- Establish connections: Connect the unit to cleaned compressed air (max. 10 bar) and power (100–240 V). Connect the red hose (conveying air) and the black hose (supplementary air).
- Fill powder: Fill a small amount of the powder to be tested into the clean application cup. For comparative tests, always use similar filling quantities.
- Set basic parameters: Select a standard program on the OptiStar 4.0 display or create a new one. For initial tests, moderate powder delivery and activation of PCC mode are recommended.
- Test run & fine adjustment: Spray onto a test part or test panel. Use DVC technology (Digital Valve Control) to adjust powder output and high voltage until you achieve the desired, even spray pattern.
- Documentation: Use the Electrostatic App (E-App) to record and save your optimal parameters for the tested powder. This makes them immediately available for the next application.
Optimal settings for typical laboratory scenarios (guideline values)
These values are starting points. Adjust them depending on powder type, part geometry, and desired coating thickness.
| Application case | Powder output (approx.) | Recommended mode | Nozzle tip |
|---|---|---|---|
| Thin test coating (color/opacity test) | 20 - 80 g/min | PCC mode: ON | Flat spray nozzle |
| Uniform layer build-up (corrosion protection test) | 100 - 180 g/min | PCC mode: ON | Flat spray nozzle |
| Coating complex parts (prototypes) | 80 - 150 g/min | PCC mode: ON, if necessary reduced high voltage | Round spray nozzle for undercuts |
| Fast color change between tests | - | Cleaning program | Clean nozzle as well |
Note: The maximum possible conveying capacity of the system is approx. 250 g/min.
Care and maintenance for long service life
Proper care is essential, especially in the laboratory with frequently changing powders, to ensure accurate results.
- Immediate cleaning after use: Thoroughly clean the application cup, the gun, and the OptiFlow injector immediately after each powder change to avoid cross-contamination.
- Check filters: The base with filter unit protects the pneumatics. Check and clean it regularly.
- Inspect nozzles: Check the standard nozzle sets of the OptiSelect Pro gun for wear or clogging.
- Keep hoses clear: Ensure that the pneumatic hoses are not kinked.
- Documentation: Use the E-App also for maintenance notes and to log cleaning intervals.
Ideal for your development and quality assurance
The OptiFlex Pro C brings the performance of the Pro series into the laboratory. Request your non-binding quotation now.
Go to OptiFlex Pro C – request priceFAQ – The OptiFlex Pro C in a question-and-answer check
1. Can I convey less than 20 g/min?
Yes, the system can be dosed very finely. The specified range (20–250 g/min) refers to stable and reproducible conveying performance. For minimal quantities, simply reduce the powder output accordingly using DVC technology.
2. What advantages does the self-fluidizing cup offer?
Thanks to integrated fluidization, the powder is optimally loosened and transported evenly to the gun. This prevents clumping and ensures a constant spray jet – essential for comparable test results.
3. Is PowerBoost technology (110 kV) not too strong for laboratory powders?
On the contrary. Especially in combination with PCC mode, it provides the required precision and controllability. You can continuously adjust the high voltage and thus set the ideal charge for each powder – whether fine white or coarse metallic.
4. What does “can be combined with any coating unit” mean?
The application cup of the Pro C is a self-contained pneumatic conveying system. It can therefore be connected not only to the supplied OptiStar control unit, but in principle also to other manual coating units, provided the connections are compatible.
Conclusion
The Gema OptiFlex Pro C is far more than just a “small” coating unit. It is a highly precise tool for powder development and quality assurance. By integrating the entire Pro series technology – from PowerBoost to PCC to the E-App – it delivers laboratory-accurate, scalable, and perfectly documented results. It therefore forms a reliable basis for decisions regarding later production use of your powders.
