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.
Cleco’s advanced tool and assembly solutions enhance user experience and increase productivity, providing powerful results for your company. They leverage new technology to increase tool accuracy, traceability, ergonomics, and safety. As a leading tool manufacturer, Cleco offers trusted tool solutions across numerous industries. Whether your company constructs high-tech automobiles, assembles planes for leading aviation projects, produces appliances, or builds earthmoving equipment, you can count on Cleco Production Tools for intelligent assemblies and world-class tools.
Cleco is very excited to present the future of connectivity, CellTek, part of our growing line-up of cordless electric tightening tools. Check out the CellTek experience!
Want to learn more about Cleco Production Tools from Air Power Manufacturing Solutions?
Click this link to view and/or download a copy of the Cleco Production Tools Catalog
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!
For collision repair centers and industrial manufacturers who own a paint booth, one of the easiest ways to protect the environment is to properly dispose of paint booth exhaust filters.
Since most paint that is sprayed contains hazardous compounds and is potentially flammable, extra care must be taken when it is time to dispose of your paint booth filters. At this time, it is not possible to recycle paint booth filters. Proper paint booth filter disposal not only ensures your business is following the law, but it is also what is best for the environment.
Here are five steps for proper paint booth filter disposal:
1. Determine If Your Used Paint Booth Filters Are Hazardous
Before disposing of your paint booth exhaust filters as general waste, you need to verify your filters have not been exposed to any of the hazardous compounds that are frequently found in paint. You must perform a Toxicity Characteristic Leaching Procedure (TCLP) laboratory test to determine if the paint you sprayed contains specific compounds. Your filters are considered hazardous if a certain amount of any of the following compounds are present in your filters:
Paint booth intake filters are designed to remove dust and other small airborne particles to supply a contaminant-free environment for painting. As long as the intake filters have not come in contact with paint, they are not hazardous. This means the intake filters can be disposed of in your normal trash.
2. Properly Dispose of Hazardous Paint Booth Exhaust Filters
If your paint booth exhaust filters are deemed hazardous, they should not be disposed of as standard waste. Instead, they must be properly stored and sent to a hazardous waste disposal facility. Store them in a non-leaking container marked with the words “hazardous waste” and a description of the waste, such as “waste paint booth filters.” Then, use a licensed hazardous waste transporter to ship the container to a hazardous waste disposal facility.
Before disposing of hazardous paint booth exhaust filters, you should always let them dry. Allowing your paint booth exhaust filters to dry typically eliminates the chance of ignitability. It is safest to subject the filters to the same curing process you use for painted products to accelerate drying of the filters and ensure they are completely dry before disposal.
3. Contact Trash Collector Before Disposing of Non-Hazardous Paint Booth Filters
Even if your paint booth exhaust filters are not deemed hazardous waste, you should notify your trash company that you are disposing of the filters as standard waste. Your trash collector may ask you to provide proof that no hazardous compounds are present in the filters. Make sure to retain documentation of the safety data sheets (SDS) of the materials you are spraying, lab test results and any other pertinent information your state recommends you keep on file.
4. Do Not Spray Gun Cleaners Into Paint Booth Exhaust Filters
Many spray gun and wand cleaners contain solvents that are classified as F-listed hazardous waste, including methylene chloride, methyl ethyl ketone (MEK) and toluene. This is indicated on the SDS of the solvent as F001, F002, F004 or F005.
Spraying solvents into the exhaust filters during gun cleaning can cause your filters to be considered hazardous waste. When cleaning your spray gun, make sure to keep solvents away from the paint booth filters. It is best to spray solvents into closable hazardous waste collection containers or use a gun washing system.
5. Test Filters Whenever You Make a Change to Your Paint Process
Determining whether your paint booth exhaust filters are hazardous waste can be an ongoing process, depending on how often you introduce new paint into your operation. Testing is required whenever parts of your painting process change.
Any time you add a new paint, you need to evaluate the paint to see if it contains hazardous compounds. Since testing can take some time, you should give yourself a buffer before you intend to spray the paint.
Regulations regarding paint booth filter disposal vary from state to state and sometimes even from county to county; your local authorities can tell you the requirements for your area. Since you cannot recycle paint booth filters, considering them hazardous waste and coordinating with a hazardous waste disposal company to dispose of them properly is the safest thing for the environment.
Source: Global Finishing Solutions
Learn More about Global Finishing Solutions Spray Booths