Silicone Drum System Saves Money

 

Manufacturing facilities in today’s competitive market strive to produce the highest quality product. In this case study we will discuss the importance of recognizing every company’s desire to produce a premier product.

Customer

Leading Global Manufacturer of Display Refrigerated Cases Systems

Air Power’s Solution

In partnership with the customer and the silicone material supplier (Ellsworth Adhesives), Air Power offered a solution by using 3 ea.  Graco 55 gallon drum packages. These drum packages will replace manual and battery operated caulking guns. By going to bulk drums vs expensive tubes customer will reduce silicone cost by 30%. Customer purchases over 1 million dollars per year in silicone. Drums are placed near three assembly stations throughout the plant. Material fluid hoses are festooned 14 feet over head at each operating station to eliminate dangerous trip hazards.

Result

By converting from caulk tubes to bulk 55 gallon drums customer will reduce RTV silicon by an estimated cost by 30%. Each Graco 55 gallon ram drum package features Graco Data Trak. The Graco Data Trak features a light tower located on the 55 gallon ram package. The light tower will alert the operator with a signal showing drum is low on material or empty.

Increased floor space by eliminating cartons of tubes placed on wood skids near each operating station. Increase production time by elimination to open cartons of tubes of silicone and place tubes into manual caulking guns.

Eliminate the need to have batteries charged. Eliminate the cost of replacing battery charged caulking guns.

 

How To Depressurize A High Pressure Pump and Flush With Solvent

How To Depressurize A High Pressure Pump and Flush With Solvent

 

In this video, Account Manager, Jeff Tussey walks through the steps to depressurize a high pressure pump and flush with Solvent. Please LIKE & SUBSCRIBE to our channel to stay updated on the latest from Air Power’s How To Series!

 

Which Pump?

How Does An Air Operated Double Diaphragm Pump Work?

 

An air operated diaphragm pump is a type of positive displacement pump that uses compressed air as a power source. The compressed air is shifted from one chamber to the other by a linked shaft that allows the chambers to move simultaneously. This back-and-forth motion, forces liquid out of one chamber and into the outlet manifold, while filling the opposite fluid chamber via the inlet manifold. Upon changeover, the fluid section that was filled on the previous shift empties into the outlet manifold and then fills the opposite chamber via the inlet manifold. The rapid changeover allows for reduced pulsation at the outlet.

How to Select an Air Operated Double Diaphragm Pump?

 

Choices are endless when selecting the correct air operated double diaphragm pump (AODD).  Aluminum? Stainless? Why Plastic?  Different chemicals require different pump components which are critical in determining the best pump solution for the application.  Not all applications are the same and neither are the pumps.  Check out some general information regarding the construction of Graco AODD Pumps.

 

Graco Process Catalog

 

 

 

 

Source: https://www.graco.com/us/en/in-plant-manufacturing/products/general-fluid-transfer/double-diaphragm-pumps.html

Increase Transfer Efficiency

 

Challenge

Customer was looking to improve transfer efficiency on their automated spindle machine spraying primer on various size metal housings.   The existing system utilizes one spray gun set a considerable distance from the parts.  This causes excessive overspray and waste.  Customer also wanted to go from using 55 gallon drums to 5 gallon pails due to settling and solvent flash off in the primer.  The 55 gallon drum sits for around 4 months.  The viscosity needed to be regularly checked and adjusted.

 

Before Before 2

 

 

 

 

 

Air Power’s Solution

Equipment utilized – Graco fixed automatic spray guns coupled to a Graco dual regulated pressure pot with agitation.  All controlled via an Air Power custom designed pneumatic control panel for system optimization and performance.

Air Power, Inc. proposed replacing their single gun setup with two guns.  These guns will be mounted on mounts that can be adjusted to effectively cover the various size parts.  This will minimize the amount of overspray and improve the transfer efficiency of the system.  The controls for this system will be contained in a centralized control box.  Fluid supply will utilize a 5 gallon pressure tank.  This will allow the operator to place a 5 gallon bucket of primer into the tank.  This system will be enclosed to minimize solvent flash off.  This will help improve the consistency of the coating as it will not need to be constantly adjusted.  The paint supply will also be exhausted in roughly a week now.  This will allow fresh primer to be sprayed, also improving consistency.

 

Results

  • Customer experienced increased transfer efficiency which saved them money by minimizing the amount of overspray and waste. It also reduced the amount of filtration they were purchasing due to the reduced overspray saving them time and money.
  • Customer reduced solvent flash off due to the switch from 55 gallon to 5 gallon pail saving the operator time from adding additional solvent to the 55 gallon drums.

 

Air Power Solution Air Power Solution

 

 

 

 

 

 

 

 

 

 

How To Properly Set Up A Binks Pressure Pot and Spray Gun Fluid Flow Rate

How To Properly Set Up A Binks Pressure Pot and Spray Gun Fluid Flow Rate

 

Equipment Utilized – Binks Dual Regulated Pressure Pot + Devilbiss Compact Trans Tech Spray Gun with 1.4mm Fluid Needle

Ist Regulator is for Pot Fluid – ie. Outbound fluid pressure. A good starting point for outbound fluid pressure is 10 lbs.
2nd Regulator is for spray gun atomization air. A good starting point for spray gun atomization air is “double” that of starting fluid pressure.

In order to set your outbound spray gun atomization air, you MUST set using dynamic air pressure (ie. With the gun trigger depressed). When setting fluid flow rate – ultimately this is determined by production demands, but in most cases your fluid stream should be between 6-12 inches from the end of a gun.

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Paint Kitchen Automation Cleans up Inefficient Mess for Equipment Finisher

 

Graco E-Flo DC Pump

Graco E-Flo DC Pump

 

This case study demonstrates how the Graco Intelligent Paint Kitchen can improve the painting process by decreasing production downtime, lowering production costs and increasing process efficiency.

Customer

Heavy-duty lift truck equipment finisher.

Challenge

 

The maintenance manager at a heavy-duty lift truck equipment finisher was left with someone else’s mess. The paint room supervisor had designed a paint kitchen for a 24-hour operation, only to leave when production changed to five days a week. With no one taking ownership of the paint room, inefficiency took over.

• Friday afternoons, the paint room attendant shut down the paint circulation, air compressor and pneumatic agitators.
• Monday mornings, they lost at least six carriers of parts and more than an hour of production time, because material had settled in the paint lines over the weekend.

Circulating the paint on the weekends meant running a 500-horse power (HP) air compressor. The energy cost savings seemed to outweigh the cost of lost parts.

 

Solution

 

The maintenance manager consulted his local distributor, who wasn’t sure how to handle the situation. The equipment they had was sound; it just didn’t provide the flexibility they needed. Their Graco account representative offered an out-of-the-box solution. The Intelligent Paint Kitchen (IPK), powered by the E-Flo DC 4-Ball Piston Pump, could allow them to reduce downtime, save on energy costs, and remotely monitor the paint room. Some of their existing equipment could even be repurposed in the new set up.

Results

 

The Graco Intelligent Paint Kitchen system automated the paint room and made their production schedule more flexible. Electric equipment avoided air compressor costs, and allowed them to keep the paint circulating during non-production times. With presets and remote monitoring controlling the paint room, efficiency is the new norm.

• Friday afternoons, the paint room attendant sets equipment on sleep mode.
• Monday mornings, production starts smoothly without loss of parts, downtime or rework.

With the help of remote monitoring, the maintenance manager now spends less time with production supervision. Their newfound efficiency allows them to
take on and scale back production as needed without overextending their resources.

 

 

 

 

Air Power Partnered with Graco on this case.

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Click Here to learn more about what Graco offers.

Ergonomics and Quality Control to New Heights

 
Manufacturers of passenger transportation systems make every effort to exceed in safety intelligence within the industry. This case study demonstrates safety improvements, as well as, operator ergonomic advantages, in an effort to decrease facility liability.

Customer

 
Manufacturer of vertical transportation systems.

Challenge

 
Operators manually load and unload valves utilizing an older pneumatic torque tool. The current tool utilized within production was non-shut off and provided no verification of installation. The operator was responsible for assuming the proper socket and torque combination capable for a successful installation. The inability to measure torque accurately resulted in an inconsistent quality of final product with no verification that it was done properly. In addition, this application proved labor intensive and was the cause of concern for operator safety and ergonomics.

Solution

 
Air Power implemented a custom Ingersoll Rand DC Electric Assemble tool, integrated into a GCI torque reaction arm, with a pneumatic clamping fixture omitting operator strain and removal before completion. Custom sockets were provided to insure precise fit.  The custom fixtured Ingersoll Rand DC Electric tool was coupled with a front end Norbar Multiplier producing actual real time torque verification and discreet I/O output, which was coupled with an Air Power provided PLC to monitor torque and track data usage.

 

 

Results

 

The solution realized by Air Power created a torque verified product that allowed for a safer work environment and smoother process for the operator. All build requirements can now be monitored, tracked and viewed through a transparent build as a result of system implementation.

 

 

 

Water is Good. But Not in Your Airline.

Compressed air is readily available and simple-to-use, but it can be the most expensive form of energy in your application. Air leaving a compressor can also be dirty, and depending on the outside temperature, can contain moisture. The presence of moisture in the air line can damage and shorten the life of downstream equipment, such as pneumatic tools and Liquid/Powder spray equipment. Unregulated or improper air pressure can result in increased compressed air demand, which results in increased energy consumption. Excessive pressure can also increase equipment wear, resulting in higher maintenance costs and shorter tool life. Before compressed air can be used it should be Filtered, Regulated and in some applications, Lubricated.

Filters

 

Filters clean compressed air. Compressed air can carry condensed water, oil carryover from compressors, solid impurities (dirt and rust) generated within the pipelines, and other wear particles from the ambient air. These contaminants can cause problems at every point of use, and should be removed by installing suitable filters.

Regulators

 

Regulators reduce and control pressure in compressed air systems. They are used to control pressure to: air tools, such as impact wrenches and sanders, liquid and powder spraying devices and many other pneumatically powered manufacturing applications. Optimally, a pressure regulator maintains a constant output pressure regardless of variations in the input pressure and downstream flow requirements. Downstream equipment flow and pressure requirements must be determined to properly size the correct regulator for the application.

Lubricators

 

Lubricators add controlled quantities of oil into a compressed air system to reduce the friction of moving components. Most air tools and other air driven equipment require lubrication to extend their useful life. The use of an airline lubricator solves the problem of too much or too little lubrication that comes with other methods of lubrication such as a grease gun or oil, as well as supplying the right kind of lubricant for the tools being used. Once the lubricator is adjusted, a metered quantity of lubricant is supplied to the air operated equipment and the only maintenance required is a periodic refill of the lubricator reservoir. Adding lubrication to a system can also prevent synthetic compressor oil build-up on system components.

Clean air is a key ingredient that enables effective and efficient operation of tools, equipment, and machinery in almost every industry. As such, the use of air preparation devices, such as filters, regulators, and lubricators (FRLs) is an excellent way to keep your air supply in top condition, as well as enabling your tools and equipment to operate at their peak performance. Air Power can help you identify the cause of your airline issues and find a solution to keep your airlines clean and controlled.

 

ARO FLO Series

 

 

 

Graco Electric Fixed Ratio (EFR) Metering System

 

 

The Graco Electric Fixed Ratio (EFR) is an electrically driven proportioner for two component sealant and adhesives. The EFR provides advanced material control in applications requiring consistent shots and beads. Air Power Application Specialist Ronnie Lowe talks about the features of the EFR Metering System and the many ways it can improve your manufacturing process.

 

Graco EFR Metering System

  • Highly accurate, even with low flow rates
  • Capable of shots, beads and continuous flow dispense
  • Superior repeatability
  • Capable of handling a wide range of materials
  • Easy to configure, operate and maintain

 

 

 

Levitate Anti-Fatigue Exoskeleton

Introducing the AIRFRAME®, a practical new device that reduces muscle stress and fatigue – making the end of the day feel like the beginning.

 

The Levitate AIRFRAME is a wearable, lightweight technology engineered to improve upper extremity musculoskeletal health in professionals and skilled trade workers who engage in repetitive arm motion and/or static elevation of the arms. The AIRFRAME lowers exertion levels by up to 80% – keeping workers healthier and more productive, while mitigating healthcare and disability costs.

 

 

 

HOW IT WORKS

 

The AIRFRAME transfers the weight of the arms from the shoulders, neck and upper back to the outside of the hips, evenly distributing energy to reduce stress. It slips easily on and off, and moves seamlessly with the wearer without intruding into the workspace or limiting motion or dexterity. The AIRFRAME’s mechanical support system progressively activates as the arm is raised, and gradually releases as the arm is lowered, resulting in just the right level of support – at just the right time. It’s personalized to fit each wearer, so they can use their arms as normal while enjoying reduced fatigue and comfort they never thought possible.
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FEATURES

Light and Comfortable
Personalize Fit
Full Range of Motion
No Power Required
The AIRFRAME’s sleek, aerodynamic design and lightweight material construction make wearing the device feel nearly unnoticeable. Each AIRFRAME is custom-fitted to the individual user, allowing the device to fit comfortably on any body type or size. The AIRFRAME offers full range of motion, allowing the user to easily perform any task without limitation or stiffness. The AIRFRAME requires no electrical power – it is mechanically engineered to rely on a patented system of pulleys.

BENEFITS

 

Lowers Injury Risk
Boosts Productivity
Improves Quality and Precision
Lowers Healthcare and Disability Costs
On-Site Training
There are more than 650,000 cases of work-related musculoskeletal disorders (WSMD) annually. The AIRFRAME lowers exertion levels by up to 80%, significantly lowering injury risk. WMSDs are responsible for $50 billion in lost productivity annually. The AIRFRAME keeps workers healthy, and production humming. Muscle stress and fatigue are the enemy of productivity. The AIRFRAME allows workers to maintain quality and precision for longer periods of time. Musculoskeletal disorders represent $1 of every $3 spent on workers compensation. The AIRFRAME limits exposure to these injuries, reducing costs and boosting profits. We offer full, on-site training for both workers and safety engineers on how to custom fit and operate The AIRFRAME for all users.