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
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Merry Christmas from Air Power Manufacturing Solutions!
We hope you have a Merry Christmas and a Happy New Year!
Returning to work safely is a global priority amid the Covid-19 pandemic. The Dyna-FAST Thermometer is a new innovation from Dynabrade aimed at helping businesses resume safe operations. Fast, contactless temperature screening is an additional, vital step every individual can take to ensure the health and safety of their colleagues. Easy, self-screening upon entry each day takes seconds and helps protect individuals, teams, work cells, and entire facilities.
- Contactless Forehead Thermometer
- Operator-Free Scanning
- Foot-Pedal Activation
- Easy-to-read Digital Output
- Includes cable, foot-pedal, upper/lower housings, and loop clamps
- Available with Thermometer (Model 62110) or without Thermometer (Model 62111)
- Works with all hand-held Forehead Thermometers
Assembly solutions often require an array of different equipment to get the desired result. In this case study, Air Power was able to design a fully ergonomic dispense solution for this customer.
Manufacturer of HVAC Equipment
This customer was planning an expansion that included adding 2 additional assembly lines for panel foaming. They wanted to have a more robust Gantry System, contrary to solutions discussed previously with other distributors. Air Power’s ability to integrate the Material Handling portion of this project along with the Dispense/Fluid Management system allowed us to be the sole solution provider the customer was able to find through the initial quoting phase. After digging into the project, the customer realized our potential and requested the Mix, Meter, and Dispense System to supply two separate assembly lines, thus adding more complexity to both portions of the MOVE project. Factors like pressure loss, high-pressure piping, distance, ergonomics were key when bringing this project from theory to paper to real life.
Air Power Solution
Our team was able to design a custom solution that utilizes a Unified Dual Cantilever Overhead Rail System, paired with a Hennecke High-Pressure Metering Machine designed to dispense the full range of rigid foams and flexible foams. This dispense system controls 2 mix heads to fill panels with a Polyurethane Foam on 2 assembly lines. This system pumps the foam through high-pressure hoses mounted overhead with an Ingersoll Rand Suspension Balancer and Z-Servo Balance Control.
This system has the ability to have cross-lateral movement spanning the entire workstation, pump foam throughout the 1000+ feet of piping/hoses, ergonomically sufficient enough to navigate the 100lbs mix heads North, South, East, West with minimal effort, and produce foam with the touch of a button. We were able to deliver all of the key factors with a combination of our vendor support, customer communication/guidance, and our internal resources to deliver a unique one-of-a-kind turnkey solution!
The Covid-19 pandemic has affected everyone in many ways. While many of us are still dealing with the effects of this, Air Power recognizes the strain this year has put on many of our employees and their families. We decided to take the time to Thank our team for being #ESSENTIAL.
Air Power put together packages for each and every one of our employees as a Thanks for their dedication and hard work through these unprecedented times. This #ESSENTIAL package was filled with fun and useful promotional gifts sponsored by a few Air Power business and vendor partners.
These sponsored gifts include: an #ESSENTIAL t-shirt sponsored by StableNet IT Services, a travel mug sponsored by Dynabrade Abrasive Tool, a pen sponsored by Sioux Tools, an Air Power/Ingersoll-Rand branded koozie, and Air Power Hand Sanitizer.
We want to Thank each of our sponsors for their support and helping us to recognize every one of our #ESSENTIAL employees.
More about: Southworth Products