Air Power in partnership with Graco is working hard to prep the Hydroshield for upcoming customer demos throughout our entire territory! Pre-plan, setup, and spray prior to demo ensures a successful onsite demo. We’d like to thank the team of Graco Representatives Nick Lewis, Nick Yanavitch, and Chris Maicon for all working with the Air Power team to establish this product in the field.
The Graco Hydroshield Spray Package is an operator-friendly solution for spraying waterborne material that improves transfer efficiency and safety. This system includes manual electrostatic air spray or air-assist guns, controller interface, and high-performing pumps.
The HydroShield Batch Waterborne System makes it easy to safely use electrostatics to spray waterborne material.
- Refill paint supply without having to open the isolation cabinet.
- Use one controller with simple screens to set and adjust system parameters.
- Minimize downtime with durable components that are easily accessed and maintained.
Check out these pictures of the Air Power team setting up this system in the Air Power High Point Finishing Lab!
The assembly process in manufacturing plants typically is the largest drain on human labor resources. Anything that can be done to speed up that assembly process is critical. Especially, if it creates a reduction of labor and increased throughput, and increased quality in the final product.
A Global supplier of compression molded plastic parts to tier 1 automotive, Heavy Truck and bus, Heavy equipment, marine, reactional vehicle manufacturers.
This company has 3 work cells installing multiple fasteners into door panels for Tier 1 automotive. They were using two tools per station (One DC, One pneumatic) and manually inserting and driving to torque 3 fasteners. This resulted in 3, 8-hour shifts of assembly 5-6 days a week to meet production demands. With this process, torque values were not being collected and there was no assurance of quality. Resulting in inconsistent quality, frequent rework, and often rejected batches of parts.
Air Power’s Solution
Air Power, Inc. in Partnership with Design Tool Inc. (DTI) proposed a solution utilizing both Ingersoll Rand DC Tools and DTI screw feeders. This would reduce Takt time thanks to the DTI screw feeders and assure consistent torque values and alert if there was an issue from bad fasteners,cross-threading, etc.
Utilizing the DC tools along with the DTI Screw Feeders we were able to dramatically reduce takt time, increase quality, and dramatically reduce the amount of labor needed to meet production demands.
- Labor was reduced from (3) 8-hour shifts running 5-6 days a week to (1) shift 4 days a week.
- First Pass quality increased by 80%
- Rework is almost non-existent because any defects in fasteners or torque are corrected or captured in the work cell instead of at the end-user or in the quality department.
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!
Air Power Airwaves Podcast Teaser
The Airwaves Podcast is all about the manufacturing industry. This show is filled with helpful tips, news about new technology, and stories of real experiences from the Air Power team. Be sure to connect with us online to stay updated on all the latest from Air Power!