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Product Demonstrations

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Product Demonstrations

Air Power Manufacturing Solutions is making efforts to be sure that we can continue to effectively support the manufacturing community during this time. We love to be able to visit customers on-site and demonstrate how the products we sell can improve manufacturing processes, but there are a variety of other ways we can show you the latest technologies. Follow the link below to read about the ways Air Power can help you improve your manufacturing process!

 

 

pRODUCT dEMONSTRATIONS

 

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

 

 

CFT Maple Smart Pump

 

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.

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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!

 

 

Improving Your Electrostatic Process

Improving Your Electrostatic Liquid or Powder Coating Process

 

In this video, Air Power Specialist Travis Stirewalt and Account Manager Eddie Rhodes, share tips about improving your electrostatic process. Learn how to improve your electrostatic process with expert advice for powder coaters and liquid painters. Discuss best practices that help you put more powder or paint on your parts and less in your filters or the paint booth floor. What does this mean for you? Higher transfer efficiency and less paint (money) wasted by increasing your first pass transfer efficiency. Video from the Air Power, Inc. Chattanooga Branch.

Troubleshooting with Graco

Troubleshooting with Graco

 

Air Power along with the help of the Graco Team, organized a troubleshooting training event. Our team spent time learning all of the Graco pump quick fixes that they can use in the field to solve issues for customers on the spot. With this training, our Account Managers can save customers time and money in service and repair costs. Thanks to the Graco team for their support!

 

Graco Diaphragm Pumps

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

 

Husky Air Operated Double DiaphragmDesigned 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 Husky 1050e PumpsGraco’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!

 

 

Learn More About Graco

Source: graco.com

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

 

 

 

 

 

 

 

 

 

 

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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