Managing the mixing and dispense of different fluids needed for a manufacturing process can be expensive, time-consuming, and dangerous for operators. Air Power offers solutions that eliminate the many pain points of the mix and dispense process.
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.
A Manufacturer of foam-filled plastic parts
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.
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!
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.
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.
The customer drastically improved production process time, labor hours, and material savings in their paint process.
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.
Manufacturer of HVAC Equipment
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.
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!
When it comes to mixing paint, accuracy is the key to achieving a high-quality finish. In this case study, we discuss a 2K solution that helped this customer perfect their process and save tons in production costs.
Manufacturer of roadside transformers.
This company has a small parts booth for primer and topcoats. The operator had to manually mix two types of epoxy and one urethane. Each day he had to spray all three colors from the same hot pot system. The color change process was a major problem as the different parts to be sprayed were not batched. This caused a lot of waste of paint and solvent. The other concern was being off ratio and parts not curing properly. This was a major cost to the company. They also had a large booth that sprayed the finished transformer. They had to utilize the same paints and this process had the same problems. If the large transformer was off ratio, they had to sand the paint off and repeat the entire process. This proved to be a very expensive problem.
Air Power Solution
Air Power proposed to install a Carlisle GEMS 2K mix system for each color. We also put in a pump system to pump and circulate all paints to the mix machines. The catalyst was dispensed to the machines from 5-gallon pressure tanks. The 55-gallon drums of paint each had an agitator in them to keep paint in suspension to maintain viscosity. By having a machine for each color there was no color change or off ratio problems.
The Air Power Solution eliminated the need to hot pot in tanks. Since each color is mixed on demand; this system provided a major labor savings. There is no paint waste and the newly established process saves about 2 to 3 hours per shift as compared to manually formulating and mixing paint. The solvent usage was greatly reduced as there was not a tank to clean each color change. This solution has been able to speed up production on all three shifts. Our technical group and installers were able to put the system in place without impeding the customer’s production runs.
Carlisle Fluid Technologies Maple Smart Pump
The Maple Smart Pump is Carlisle Fluid Technologies’ advanced, air-operated, horizontal piston pump for automotive and general industrial applications. This range of precision-engineered pumps is designed to handle modern shear sensitive solvent and waterborne paints as well as pure solvents and other paint shop materials. The Maple Pump design combines an energy-efficient air motor with CFT’s low shear fluid section technology providing a smooth consistent flow of materials for both automatic and manual spray gun systems.
LIKE & SUBSCRIBE
Graco designs and builds a wide range of equipment designed to handle industrial fluids such as inks, colorants, paint, abrasives, corrosive, shear sensitive, gas entrapped and more. They also design and build custom products for customers with unique requirements. Graco’s double diaphragm pumps are designed for chemical transfer applications. Their chemical transfer pumps come in pneumatic and electric options, with many flow rates and sizes. Both metal and plastic housings can easily handle corrosive and abrasive fluids. They design and build the Husky double diaphragm pumps to hold in the harshest working environments. The best materials and the highest quality standards results in pumps that are built to last.
Graco Husky Double Diaphragm Pumps
The Husky double diaphragm pumps are manufactured with your productivity in mind – providing you with one of the most reliable and efficient pumps in the market. Each membrane pump is thoroughly tested before it leaves the factory.
Husky Air Operated Double Diaphragm
Designed with fewer parts than competitive pumps, Graco’s air operated double diaphragm pumps features our stall-free, low pulsation air valve, which is externally accessible—ensuring rapid changeovers and minimum downtimes.
Advantages of the Husky Air Operated Diaphragm Pumps
- Rugged construction – Resists corrosion for reliable performance and long life
- Designed to last – Heavy duty design offers long life, increased productivity and lower overall cost of ownership
- Flow rates and sizes – up to 300 gpm (1135 lpm) / port sizes ranging from ¼” to 3” in NPT, BSP, and flange options.
- Easy maintenance – The Husky has fewer parts than industry peers, the complete air valve is externally accessible so it can be serviced fast and easy without removing the pump.
- Modular air valve – Stall-free, low pulsation air valve provides smooth and rapid changeover for increased efficiency and minimizes down time
Husky Electric Operated Double Diaphragm Pumps
Graco’s electric double diaphragm pumps (EODD) are ideal for applications that require low pulsation and a smooth flow. The energy efficient electric drive reduces energy consumption up to 5x compared to traditional air operated diaphragm pumps. Each pump is ruggedly constructed to resist corrosion and deliver a long, trouble-free product life.
Advantages of the Husky Electric Operated Diaphragm Pumps
- Durable Pump Technology handles slurries and abrasives all without damage to the pump
- Fluid section is fully customizable allowing user to create the pump you need with multiple material offerings for manifolds, seats, balls, and diaphragms.
- Diaphragm pump is self-priming, runs dry and requires no rotating or moving of fluid seals
- Electric Drive reduces energy consumption and operating costs
- Provides increased pump control and accurately meters fluid
Contact your Air Power Representative today to find out how you can revolutionize your process with Graco Double Diaphragm Pumps!
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.
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.
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 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.