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.
Heavy-duty lift truck equipment finisher.
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.
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.
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.
The Air Power Sales team attended Graco’s 2019 Finishing Series Launch Event. It was held at the Georgia Power Center in Atlanta, GA and GEMA’s Training Facility located in Indianapolis, IN. This exclusive training is designed around Graco’s extensive product and application knowledge further equipping our team of Account Managers and supporting Application Specialist’s ability to support, promote, and identify opportunities within the manufacturing community. We were able to receive 10 hours of hands-on training directly with Graco’s team of product managers, engineers, and marketing leaders; allowing for a successful and mutually beneficial event. This training centered around cutting edge technology and product enhancements; with topics including: product messages, combating competition in the field, and proven examples (case studies) of how these technologies solve customer challenges. Below are the seven (7) topics that the Air Power and Graco team covered in detail.
Intelligent Paint Kitchen for Pneumatic Pumps
Graco’s intelligent paint kitchen is a system of smart sensors communicating with each other that optimize the performance of your circulation system. It is a less complex, less expensive alternative to advanced remote monitoring and control for the entire paint room — especially when compared to traditional custom built systems. All components are standard products, not a custom-built system, which makes them easy to be configured and install. And because both the initial investment and installation costs are lower, you’re able to be more competitive in a global market. With the intelligent paint kitchen, you can remotely monitor and control key circulation system parameters like pressures, flow rates, tank levels and agitator speeds. The enhanced awareness of key circulation system parameters in real-time enables quick diagnosis of issues and ensures your system is operating at peak efficiency.
New Pro XP Electrostatic Gun Models
Graco took their trademark, high performing electrostatic spray guns and made them better. They are smaller, lighter and designed to maximize your profits. Available in 40, 60 and 85 kV, the Pro Xp electrostatic spray gun also has a round spray option for when you need a bell-shaped pattern and a High Conductivity version for when you have low resistivity material.
Radial Piston Agitator
These units consume 30 to 50 percent less air than rotary vane motors. Manufacturers can upgrade to radial piston agitators, which run the most efficiently at low to medium speeds.
Sealed 4-Ball Plus Lower
Graco’s sealed lower not only has longer maintenance cycles, but it is also easier, faster and cheaper to replace than an entire pump assembly. The lower is completely sealed, so it can be used for every pumping application in your mix room, including catalyzed coatings. Common components make it simpler to maintain your pump, and it reduces inventory level on repair parts. Plus our positive displacement piston pumps displace fluid in both directions of the stroke, providing low cycle rates and high flow, ideal for applications using shear-sensitive materials.
Active Surge Suppressor
Graco surge suppressors were designed specifically for the finishing industry from decades of pump technology research. The streamlined fluid path ensures low shear, smooth fluid flow, and superior flush ability.
Graco’s ProDispense is a cost effective, user-friendly electronic system that gives you the capability to quickly and accurately fill cavities with industrial fluids in assembly line environments. The ProDispense allows for Consistent fluid dispense that is compatible with manual or automatic applications. The easy to use interface allows for the tracking of volume. The fluid panel configurations allow for a wide range of material viscosity and flow rates with accuracy ranges of 1 to 3 percent.
Graco’s ProControl 1KE allows you to actively manage fluid and air pressure to lock in precise spray parameters. It not only monitors fluids, it has added controls to manage fluids and improve spray performance. These systems allow for precise control of pressure, flow rates, and atomizing air with the ability to easily adjust. The user interface allows for accurate reporting of material usage while remotely monitoring all fluids via the advanced web interface on your corporate network.
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.