Controlling Viscosity through Proper Temperature Control

Problem

Automotive manufacturer was having trouble controlling their paint viscosity with the change in temperature in their facility from morning to afternoon.  The customer was constantly changing fluid pressure to try and keep up.

Air Power Solution

Controlling Viscosity

With Air Power’s partnership with Saint Clair Systems we offered the customer a solution providing them with a Temperature Control Unit and heat exchanges for each color for each of their spray booths.

The Customer Experienced the following benefits:

  • Maintained constant viscosity at point of use to their automatic spray system.
  • Reduced re-works which reduced labor and paint costs.
  • Learned about other deficiencies by maintaining constant viscosity
  • Improved and kept a consistent appearance on all vehicles

Effect

The above benefits save the customer TIME and MONEY!

Controlling Viscosity Setup

 

Isolated Paint Control Panel Brings Consistency and Speedy Changeovers to the Production Line

Problem

A local gearbox manufacturer has had ongoing issues with multiple paint operators making changes to the paint system throughout the day. They rotate painters every couple of hours so the paint quality and consistency is all over the board throughout the day. We have isolated the spray gun controls and implemented electrostatic painting but they still have issues. All colors run through a manual color change manifold and fluid pressure regulator which limits the fluid pressure even when color changing. There are also issues when the colors aren’t changed on a long run that the other colors settle out in the lines.

Air Power Solution

Paint Control Panel

Air Power built a custom, lockable, control panel with a multitude of controls for the company and for the operators.

  1. Hi/Lo fluid pressure settings though independent air regulators controlling a single Graco air piloted fluid pressure regulator. These are set with supervision and management and are locked from the operators. They have 2 fluid pressures to select from and nothing else to minimize operator adjustments. Pressure selected is visible via included gauges.
  2. Select-able color valve stack via a rotary control to select the color being sprayed as well as the solvent flush.
  3. Graco back pressure regulators on each recirculating line for the 3 colors to allow paints to recirculate when not in use.
  4. Atomizing air pressure adjusted internally and locked out from the operators.
  5. Integrated inlet air filtration to ensure clean, dry air to feed the spray gun

Effect

This solution will eliminate the operators each making many adjustments throughout the day and tighten the quality and consistency of their paint process. It will also speed up color changes now that they are select-able via the color stack rotary control along with a flush setting that will allow full solvent pressure to clear the lines. When the flush cycle is selected the atomizing air will be cut off to eliminate the estat safety concern associated with a solvent flush. The re-circulation of the colors will improve the quality and consistency of each color when selected via the color stack. The integrated air filtration will extend the service life of the spray gun while improving the quality of the paint process also.

Graco HydroShield Electrostatic Spray System

Air Power in partnership with Graco is working hard to prep the Hydroshield for upcoming customer demos throughout our entire territory!  Pre-plan, setup, and spray prior to demo ensures a successful onsite demo. We’d like to thank the team of Graco Representatives Nick Lewis, Nick Yanavitch, and Chris Maicon for all working with the Air Power team to establish this product in the field.

The Graco Hydroshield Spray Package is an operator-friendly solution for spraying waterborne material that improves transfer efficiency and safety. This system includes manual electrostatic air spray or air-assist guns, controller interface, and high-performing pumps.

 

 

 

 

The HydroShield Batch Waterborne System makes it easy to safely use electrostatics to spray waterborne material.

  • Refill paint supply without having to open the isolation cabinet.
  • Use one controller with simple screens to set and adjust system parameters.
  • Minimize downtime with durable components that are easily accessed and maintained.

 

Check out these pictures of the Air Power team setting up this system in the Air Power High Point Finishing Lab!