Filter Conversion to Eliminate Overspray

 

Overspray in industrial finishing applications is one of the most common causes of parts being rejected by quality control inspections. This can result in constant costly reworks and low-quality finish on parts. In this case study, Air Power proposes a solution that completely eliminates overspray for this customer.

Customer

Manufacturer of plumbing and water-related fittings and valves

Challenge

This customer was experiencing paint buildup on their booth due to overspray. This was caused by inefficient airflow through the booth. This customer was using an old baffle style booth that uses offset layers of metal to catch the initial overspray and then redirects the overspray into the second layer of filters. As a second layer of filtration, the customer used Styrofoam baffle filters that allowed a high volume of bypass of a mixture of tacky and dry overspray. This type of baffle filter works better with wet paint overspray.

Without proper airflow collecting the overspray in the booth, this customer experienced a higher number of rejected parts, a lower quality finish on products, and paint buildup on their spray booth and surrounding areas.

Overspray build up

Overspray Build-up inside Booth

Air Power Solution

 

Air Power proposed a solution that updated the filtration system to a more efficient style. This solution included completely removing the metal vertical baffles that were the first stage of filtration. The second stage Styrofoam baffle filters were then removed and the 20×20 grid was scraped clean of all the overspray buildup.  Then we installed Kem-Wove P3 20×20 panel filters in the second stage, installed snapper bars on the front of the filter wall, and added RP 3252 paper/poly blankets (RTT Engineered Solutions / Col-Met) as the first stage of filtration to improve overspray capture and airflow.

Baffle Style Filter Wall

Baffle Style Filter Wall

Filter Install

Results

 

This customer was amazed by the change in airflow and overspray capture in their spray booth. This new filtration system collected all the overspray in the booth and allowed nothing to bypass for the first time. These changes improved the painting conditions for operators in the booth, allowing for a higher quality finish on products. This customer is currently in the testing stage with this system to determine the length of life for one layer of filtration to ensure this system is cost-efficient and establish best practices for their finishing operation.

 

 

 

Air Power in the News Again

Air Power has been featured by Finishing and Coating in a full-length article that highlights Air Power’s recent growth with the Zenmar acquisition. The article also talks about Air Power’s rich history in the manufacturing industry and the services we provide to the manufacturing community. We’d like to Thank Tim Pennington and the team at Finishing & Coating for recognizing our impact in the manufacturing community.

 

Air Power Article

 

What Air Power Offers

What Air Power Offers

For over 50 years, Air Power has worked closely with our customers to learn about what they needed the most. As a result of those years of building partnerships with our customers, we were able to identify a demand for services that were not offered elsewhere. We are proud to offer an array of products and services that differentiate us from our competitors. Watch this quick video about all that Air Power has to offer our customers.

The Megger: How Well are Your Parts Grounded?

 

Profitability and first-pass transfer efficiency are vital to any finishing operation. Ground is critical and there is a huge difference between thinking you have a good ground and knowing it. Why risk your profits to bad ground when it is simple to measure where you are at right now? Time to introduce THE MEGGER and exactly what it tells us about ground.

 

Check out some of our other videos about Electrostatic Finishing!

Brand Page Updates

 

Air Power has been hard at work optimizing our website. Our goal is to be a better source of information for our manufacturing partners. If you are subscribed to our monthly Power Post newsletter, you can stay up to date on all Air Power news. Air Power creates videos, case studies, and blog articles centered around the latest news from the manufacturing community. We have updated our website to categorize all of our content by the brands mentioned. These updates make all of our content visible on each brand page, which allows you to find the information you need more efficiently.

Check out the “Our Brands” page on the Air Power website:

Our Brands

 

We have updated our brand pages to include all of our Air Power content that mentions the brand. Each Brand page now has a feed of videos and case studies that correspond with each brand.

 

Graco Brand Page

 

Brands Page

 

Follow these links to check it out!

Graco Logo

Ingersoll Rand


Ingersoll Rand Controller paired with FlexArm

 

Air Power Technical Specialist James Stanley demonstrates the capabilities of an Ingersoll Rand InsightQC Controller paired with a FlexArm Smart Arm with DOGA DPC Touchscreen allowing the operator to enter sequence patterns quickly and efficiently. Visit us at airpower-usa.com or call us at 1(800) 334-1001 to hear more about this system!

Air Power Chattanooga Branch

 

Take a Virtual Tour of Air Power Chattanooga

 

Located along the Tennessee River in the foothills of the Appalachian Mountains is our Chattanooga, TN branch. This is the 3rd largest Air Power branch. This team, led by Chris Case took home the coveted Branch of the Year trophy for 2017. This branch also serves as Air Power’s Authorized Gema Service and Repair Center. Service Techs Adam and Alex work diligently to make speedy repairs and keep customers up and running. This branch also offers counter sales and maintains a warehouse of wear parts convenient for our local customers.

Get the Perfect Ratio with GEMS 2K

 

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.

Customer

 

Manufacturer of roadside transformers.

 

Challenge

 

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.

 

Results

 

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.

 

GEMS 2K Mix System

 

 

Lee Patterson Co. Virtual Tour

 

 

 

Lee Patterson Co. Virtual Tour

 

Air Power Manufacturing Solutions recently acquired Lee Patterson Co. in 2019. This location now serves as our Orlando, Fl branch location. Here is a brief introduction of Lee Patterson Co. Air Power now has the capabilities to provide our ASSEMBLE, MOVE, and COAT services in the Florida area!