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Silicone Drum System Saves Money

 

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.

Customer

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.

Result

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.

 

Save Time and Paint with ProDispense

Manufacturing facilities utilize various types of coatings, some of which are two component paint.   These formulas must be mixed properly in order to properly adhere and perform in the field as designed.  This case study highlights a solution that allowed the customer to maintain tight paint ratios, minimize waste, and remove hand mixing from the process.

Customer

A leading manufacture within the truck and bus industry located in North Carolina.

Challenge

This truck and bus manufacturing facility has multiple paint booths due to their high volume, high quality, and high standards associated with the paint application.  They use a two component primer and paint, and have to maintain automotive quality finish on their production line.  The main paint line utilizes a Graco Proportioning System to dispense on ratio paint to operator; however the offline paint repair/touch up facility still relied on manually mixing (or “hot potting”).  Hot potting tended to be very wasteful as the paint mixed wasn’t always sprayed prior to gelling, or the two parts were mixed off ratio causing imperfections within the finish aesthetics and quality.  Due to hot potting the general work area was considered “messy” as operators were physically hand mixing paint and catalyst out of drums.

Air Power’s Solution

Air Power in partnership with Graco, proposed a solution utilizing the Graco ProDispense platform of product.  This proportioning solution allows the offline operators to mix exactly how much they need for each application on ratio every time. There is no guesswork when it comes to material being mixed or how much is needed, and the work area is self-contained with little to no mess. The offline paint process has become streamlined as the paint operator only has to know how much paint he needs (in liters) and what color.  They select the desired paint volume and color from a custom touch screen user interface. Once selected the exact amount is dispensed and mixed into the paint applicator.  The operator then removes the paint applicator and performs the associated painting task.

Result

Operators are no longer mixing paint by hand.  This alone has saved the company time and money due to costly mistakes associated with the hand mixing process.  The waste output has been reduced due to the ability to accurately and repeatedly meter, mix, and dispense the exact volume of paint in which the operator needs on time and on ratio.  Aesthetically the workspace is much cleaner.  An added benefit to management is the ability to now view, track, and have visibility of paint usage, due to the ProDispense reporting capabilities, within an application which historically has had none.  Allowing for better ontime tracking, shipment, and forecasting.

 

 


 

Graco’s ProDispense is a cost-effective and user-friendly electronic system that dispenses preset amounts of fluids. The ProDispense system allows durable goods manufacturers to quickly and accurately fill cavities with oil, grease, water, or other industrial fluids in assembly line environments where accurate dispensing is essential. ProDispense can deliver up to eight different fluids at multiple dispense points, and accurately measure volume.

  • Consistent fluid dispense
  • Reporting capability tracks volume and usage
  • Easily connects to PLC and barcode scanners
  • Return on investment assures that ProDispense quickly pays for itself
  • User interface provides simple operation and data entry
  • Local or integrated control
  • Manual or automatic dispense
  • Tracks dispense results for process verification

 

 

 

 

 

Air Power Puts the Graco ProMix PD2K to the Test with HB Fuller

Air Power Manufacturing Solutions Put PD2K to the Test with Graco and HB Fuller

 

The customer is switching to Swifttak 4431 Heat Reactivated Water Based Adhesive, a two-component adhesive, for better product quality. They need a system to effectively mix and spray the 2K adhesive. The Graco PD2K is the only 2K system that can effectively handle the Swifttak adhesive due to the industrial pump based unit which allows for operation in either flow or pressure made.

More about Graco ProMix PD2K System

More about Graco ProMix PD2K System

The ProMix PD2K mixes the material close to the gun so the flush zone is significantly smaller. This allows customers to use less paint, spend less on disposal costs and allows for faster color changes. And because there is limited mixed material in the system, the ProMix PD2K is ideal for short pot life materials. It is also compatible with acid-based materials.

Graco has specific ProMix proportioners that are designed to manage tough acid catalyst applications like cabinetry and bar countertops. The corrosion resistance fluid section, plus the smart fluid plate with 316 and 17-4 SST catalyst sections, can easily handle strong acid catalysts.