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!

From Obsolete to Upgrade

 

Many manufacturers struggle with finding new parts to maintain old equipment that is integral to their manufacturing process. In this case study, Air Power finds a solution to replace obsolete equipment and get this customer back in production.

Customer

A Manufacturer of foam-filled plastic parts

Challenge

The customer was having trouble with their old, worn-out mix valve on their dispense system. The old equipment needed repairs that required parts that had been discontinued by the manufacturer.  Every 45 minutes of runtime the customer would have to swap heads and do a cleaning on the used head. The customer was informed that a newer version of their system would become available, but they simply could not wait any longer and needed a solution today.

 

Air Power Solution

Air Power Account Manager Matt Graham proposed a Graco HFR with a Paradyne  Two-Component Dynamic Mix Valve to replace the existing equipment. The Graco Paradyne Dynamic Mix Valve is a rotary static valve that consistently mixes and dispenses materials requiring exceptional mixing energy. Engineered with rugged components and precision controls that eliminate dispensing inconsistencies, reduce maintenance downtime, and optimize material usage.

The Paradyne Valve Reliably mixes and dispenses difficult foaming polyurethanes, low viscosity silicones, and other hard to blend two component chemistries.

  • Easily integrates with Graco meter, mix, and dispense systems like the EFR, PR70, or HFR for a complete dispensing solution.
  • Control system delivers precision RPM control, and real time monitoring for dispensing process stability.
  • Built with durable check valves and disposable mixers that reduce maintenance and downtime.

This solution allowed the customer to be back in production quickly and allow them to continue to use their current process. With the help of our Dispense Specialist team; Jeff Pittman, Adam Kearns, and Neal Cutler, we were able to find a solution that integrated into their current system to minimize downtime and the cost of the upgrade.

 

Install_Graco Voltex Mix Valve

 

Results

 

This customer was extremely happy with the results. They are back in production with no hiccups. The Graco HFR and Paradyne mix valve integrated seamlessly with their current process.  Air Power’s solution saved them money in downtime and integrated with their current process to minimize costs.  The new system allowed the customer to run for four hours without any maintenance and at the end of four hours they just have to change the static mixer. They are happy to be back in production and planning to upgrade a few more systems with the help of Air Power Manufacturing Solutions! If you are interested in upgrading equipment in your manufacturing facility, Call Air Power today!

 

Dispense_Graco_VOltex

Spray Finishing Made Mobile

In this case study, Air Power Account Manager Austin Lambright helped this customer eliminate pain points in their finishing process, allowing them to save time and money in production costs.

 

CHALLENGE

The customer has a 90ft DOD aircraft that is coated with a very short pot life, a very expensive material. Because of the short pot life, several painters would have to mix an individual pressure pot and all spray the plane at the same time. This caused a lot of waste in material and was time-consuming.

 

AIR POWER SOLUTION

By using a mobile cart with a large Graco EnduraFlo 4:1 diaphragm pump, we are able to feed 4 painters with one central paint vessel. This not only cuts down on a lot of waste, but also simplifies the prep and clean up process, ultimately saving money both in material cost, maintenance, and production time. An all-around process improvement.

 

Graco Endura Flo Cart Solution

 

RESULTS

The customer drastically improved production process time, labor hours, and material savings in their paint process.

 

Graco Endura Flo Cart2

 

Graco Endura Flo Cart

2020 REWIND

12 Days of Christmas Giveaway

12 Days of Christmas Giveaway

 

Air Power would like to announce the 12 Days of Christmas Giveaway! Starting today we are giving all our followers an opportunity to participate to win some AMAZING prizes! Over the next 12 Days we will post an image of our awesome prizes and ask you to Like and Share the post to participate. You will have 24 hours to engage with this post to be included in the drawing. The rules of the giveaway are listed below:

  • Participants must Follow Air Power on either LinkedIn, Facebook, Twitter, Instagram, or Subscribe on YouTube to be entered in the drawing
  • You must Like this post for 1 entry and/or Share the post for 2 entries
  • Participate between Dec 13th – Dec 25th
  • All Participants must be 18 years or older
  • Air Power Employees or Air Power Vendor Suppliers are not eligible for prizes.

We will announce the winners every day on all our social media channels. Connect with us to stay updated!


 

And the Winners Are . . .

 

Day 1- Joe Makr

Day 2- Jack White

Day 3- Steve Grubb

Day 4- Robert Hooven

Day 5- Tim Lintz

Day 6- Jon Jay

Day 7- Gary Turner

Day 8- Christopher Sweeps

Day 9- Johannah Brookwell

Day 10- Mark Foster

Day 11- Laura Kornak

Day 12- Ashley Shelton

 

Ergonomics Meets Dispense

 

Assembly solutions often require an array of different equipment to get the desired result. In this case study, Air Power was able to design a fully ergonomic dispense solution for this customer.

 

Customer

 

Manufacturer of HVAC Equipment

 

Challenge

 

This customer was planning an expansion that included adding 2 additional assembly lines for panel foaming. They wanted to have a more robust Gantry System, contrary to solutions discussed previously with other distributors. Air Power’s ability to integrate the Material Handling portion of this project along with the Dispense/Fluid Management system allowed us to be the sole solution provider the customer was able to find through the initial quoting phase. After digging into the project, the customer realized our potential and requested the Mix, Meter, and Dispense System to supply two separate assembly lines, thus adding more complexity to both portions of the MOVE project. Factors like pressure loss, high-pressure piping, distance, ergonomics were key when bringing this project from theory to paper to real life.

 

Air Power Solution

Our team was able to design a custom solution that utilizes a Unified Dual Cantilever Overhead Rail System, paired with a Hennecke High-Pressure Metering Machine designed to dispense the full range of rigid foams and flexible foams. This dispense system controls 2 mix heads to fill panels with a Polyurethane Foam on 2 assembly lines. This system pumps the foam through high-pressure hoses mounted overhead with an Ingersoll Rand Suspension Balancer and Z-Servo Balance Control.

 

Ergonomics Meet Dispense

Results

This system has the ability to have cross-lateral movement spanning the entire workstation, pump foam throughout the 1000+ feet of piping/hoses, ergonomically sufficient enough to navigate the 100lbs mix heads North, South, East, West with minimal effort, and produce foam with the touch of a button. We were able to deliver all of the key factors with a combination of our vendor support, customer communication/guidance, and our internal resources to deliver a unique one-of-a-kind turnkey solution!

 

Ergonomics

 

Ergonomics_HVAC_ASSEMBLY

Ergonmics Dispense Assembly Solution

 

Ingersoll Rand Ergonomics Reduce Injury Risks

 

One of the most common workplace injuries reported is muscle strain due to repetitive motion.  Manufacturers are seeking ergonomic material handling solutions to reduce the risk of injury for operators. In this case study, Air Power proposed a solution that successfully eliminated the risk of injury for these robotic machining cell operators.

Challenge

 

This customer had dealt with various injuries due to the operators handling parts of various sizes/weights while loading and unloading parts onto automated infeed/outfeed conveyors on robot machining cells. Hand and finger injuries were commonly reported, as well as various back injuries. The customer required a solution that was safe and easy for operators to use. The solution needed to be located out of the way of forklift traffic and out of the work area of the cell so as not to impede on the operator’s workspace. They needed a device with the ability to grasp multiple sized parts without hassle. This solution also required a system that was low maintenance, durable, with low compressed air usage.

Air Power Solution

 

Ergonomics

Air Power proposed an Ingersoll Rand column mounted with a 10ft reach and articulating arm. This system mounts out of the work cell yet reaches into the work cell to reach the work area for loading and unloading. It includes an integrated 500lb air balancer for lifting/lowering with the ability to adjust both the lifting and lowering speed to dial in the exact application. This device features low rotational inertia for ease of use and improved ergonomics for the operator, low maintenance, low CFM usage per cycle.

This Custom Air Power/Ingersoll Rand Manipulator is made of heavy steel for durability with pistol grip controls and a dummy handle for ease of use and maneuverability. It includes single-hand controls for lifting/lowering of the device & clamping/unclamping of parts, safety interlock that is load sensing to prevent parts from being dropped once elevated off the work surface, V-shaped movable jaws to allow clamping of various sized parts, padded jaws to prevent damage to machined surfaces, and requires little to no maintenance.

 

 

 

ErgonomicsErgonomics