Posts

Powder booth Airflow issues solved by an Air Power Dynamic Duo

Problem:

The client, a local manufacturer, was having air flow issues within it’s paint operation. This was causing major dust/powder buildup in the nearby areas of the plant. Not only this, but the inefficiency of the airflow was hampering overall plant performance.

Solution

After on onsite review with the customer, Chris Case (Account Manager) and Travis Stirewalt (Technical Specialist) were able to determine that the 2nd and 3rd stages were horribly neglected. In addition, we pointed out that although airflow with no filters and clean filters was excellent, the airflow with the clogged stage 2 and 3 were causing the issues.  We installed the Kemwove filters during a one day trial and testing period of the filter process. Two weeks later, we revisited the plant to check on the filters and then again a couple of weeks after that. The customer had moved into some of their old first stage inventory (paint pockets) but had left our 2nd and 3rd stages alone as requested. The 2nd stage filters were absolutely full and had spared the bulk of powder capture leaving the 3rd stage pocket filters in great shape.

Results

With the collected data over the test and review period, we were able to provide a concise filter plan and maintenance schedule for monthly, quarterly and annual review.  For this customer – better air flow, improved plant performance, and a reduction of annual filter costs!

 

Filter Troubles

A client needed faster color changes…Air Power and Gema to the rescue

Problem:

Our clients operators were already using Gema box units for their non-recovery powder booths. While the units worked wonderfully these booths were connected and would be considered opposing. Each time they need to change color the operator must lift a 50lb box on and off the vibrating platform. This was a huge ergonomic issue for everyone involved.

Solution

After reviewing the setup and assessing the clients daily needs it was obvious that a Gema 8 color quick change package would allow for faster color changes, reduced material handling of the boxes of powder and would better prepare hard to fluidize powders in hoppers verses vibrating box units.

Results

Any time you can make a client’s operation more efficient, save wear and tear on their operators and show the how quickly the ROI would balance out….they are going to be happy. You almost always have to spend money to save money so having a team that understands your operation and knows all the available options to increase productivity is vital. Team Air Power got the job done once again.

Gema Quick Color Change Systems

 

 

 

 

As temperatures begin to get hotter, viscosity is very much at play when picking the proper pump.

Problem:

When specifying the proper pump for any fluid application understanding the properties of the fluid to be handled is of the upmost importance.

Viscosity…. is one of, if not the most important variable when determining the proper specification of a diaphragm pump (or any pump) and associated flow rates. The viscosity of many materials fluctuate as ambient temperature’s change through the seasons and as plant conditions change month to month, so understanding the effect viscosity has on sizing pumps is important.

Solution

All AODD pump ratings are with water at the pump outlet. For example, a Graco 1050 pump is a 1″ ported pump rated at 50 gallons per minute (water at the pump outlet).  When looking to specify the above example pump, three things must be further evaluated to insure proper performance/specification – Viscosity (will alter flow rate), available air pressure at the pump, pipe or hose size (at pump outlet all the way to the point of discharge).  Once you have determined these variables you can properly select the perfect pump for your unique application.

Results

Getting the right pump will make a world of difference in the efficiency of your set-up. Not only will your flow rates remain stable throughout the year, but downtime will be reduced and the life of your pump will be extended.Perfect Pump

 

 

 

Graco Endura-Flo pump solves multiple issues for large paint booth

Problem:

The customer came to Air Power wanting to upgrade their pump package that supplies material from their paint kitchen to two applicators on each end of their booth.  The booth runs 60’ long, with a width of 20’ and would be used to touch up dump truck beds.  After running a pressure drop calculation we determined that the material could fall out of solution if there were a day or 2 that no spraying was needed.

Air Power Solution

After reviewing the application with the customer, Air Power proposed using a 3:1 Graco Endura-Flo pump.  This option allows for the 3x the pressure, which was more than enough to overcome any pressure loss during the materials travel, as well as, has a much larger fluid section requiring less wear and tear on the pump while in operation.  Since this is strictly a touch up process and not guaranteed to be an everyday event, we also recirculated the fluid lines to prevent any material from falling out of solution.

Results

This solution provided more than enough pressure to power the required spraying.  Additionally, if there’s an occurrence where the system isn’t used for several days, the customer only has to run the pump a few minutes before spraying to move the stagnant material back within the agitated drum requiring no waste or quality concerns.

The Air Power solution solved the pressure problem, the potential solution issues, and provided a much larger fluid section to prevent wear and tear.

 

 

 

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.