Color Application, Changeover, and Recovery · reduce lost coatinggps and solvents…speeds up the process to 30 – 45 seconds depending on the coatings 2. Automatic controlled cycle

Color Application, Changeover, and Recovery

Presenter: Don Leblanc Director, Finishing Technologies

Copyright 2013 Stiles Machinery

Outcomes from the Presentation

Understanding of how color/coating flexibility can be achieved with minimal impact on performance in an automated system

Clearer vision of what is available technically Better feel for the economic impact for new high-

performance technologyUnderstanding of the environmental impact

possibilities


Market Demands for Finished Products

Hi h Q litHigh QualityIncreased color gamut / selectionMultiple gloss top coat choicesEnvironmentally compliant finishesEnvironmentally compliant finishesLow / no cost impact for above


Manufacturer Response to Market Demands

Apply automation to ensure high qualityApply automation to ensure high quality resultsEngineer a solution to allow fast coatingEngineer a solution to allow fast coating

changes on the flyR d d i i hReduce costs during coating changesReduce cost of laborReduce environmental disposal costsIncrease speed to meet demands ofIncrease speed to meet demands of

marketCopyright 2013 Stiles Machinery

Consider the Following:Consider the Following:What if you could avoid this?

Environmental hazardhazard

Confusion for the operatorthe operator

Unsightly workplaceworkplace


Consider the Alternative!Consider the Alternative!

Multiple materials

il blavailable Automatic

changeover1 2 3 4 5 6 7 changeover

No confusionE i t ll

7S

Environmentally friendly

Clean and tidyClean and tidy


Principle of Color ChangePrinciple of Color ChangeMultiple colors ready for spraying the parts p y p y g p


Color Change System-Old or New Technology

Automated color change systems have been g yaround for years

To change color, coatings and solvent between manifold and guns must be purged in fairly large quantities due to placement of the system

l ti t th d b frelative to the guns and number of gunsOlder technology systems use multiple pumps

and either manual or pneumatic manifold valvesand either manual or pneumatic manifold valves to change from one color to the other

Some newer technologies have PLC controls toSome newer technologies have PLC controls to automate this operation


One touch color change system

Uniquely designed to minimize colorUniquely designed to minimize colorchangeover time while maximizingtransfer efficiency.


Color Management SystemColor Management System Color changed at the

manifold Old color and solvent wash

lost between manifold and spray gunsManifold spray gunsManifold

Solvent

SolventDifferent Colors or Coatings


So…What is the Latest Innovation?

Three unique innovations in one systemThree unique innovations in one system1. Color change is made close to the guns to

reduce lost coatings and solvents…speeds g pup the process to 30 – 45 seconds depending on the coatings

2. Automatic controlled cycle of color change directly from the PC control on demand for i l t i bilitsingle part processing capability

3. Unique solvent purging system, IAR, to d l h d d l tspeed up color change and reduce solvent

consumptionCopyright 2013 Stiles Machinery

How is it Unique and Innovative?

Hose length isLost During Color Change

Time

Minimal Loss

Hose length is -Coatings & Solvent-Time

Color change is accomplished optimally by the position of components, reducing time g p p y y p p , grequired for color changeSupply and return lines are run for each color to the changing manifold on the actual reciprocating carriage of the machineDistance from manifold to guns is minimized and loss of coatings and solvent is low


Color Change on the Reciprocating C i !Carriage!

PC Control – Color ChangeChange

Color Change Circuit Mounted on the Reciprocating CarriageCarriage

Flush / Waste


Actual SystemActual System

Reciprocating Mechanism

Valves for Color Change & Solvent Flush

Valve for Compressed AirValve for Compressed Air


PC ControlPC Control

Simple handling of color change bySimple handling of color change by automation and color / coating listBarcode scanning or RFID ideal for

identification of next colorCopyright 2013 Stiles Machinery

Interval Air pressure RinsingInterval Air pressure RinsingOld technology systems use a solid flow of solvent to flush the old coatings from the linessolvent to flush the old coatings from the linesHigh volumes of solvent are needed to adequately purge out the old colors

Solvent

SolventDifferent Colors


Interval Air pressure RinsingInterval Air pressure RinsingInstead of using a constant fl th IAR lt tiflow, the IAR uses alternating flows of solvent and compressed air

Less solvent consumption Better cleaning resultsBetter cleaning results Faster rinsing, time saving

Thi k S bbiAlternating valve Think…Scrubbing Bubbles!

Compressed airSolvent


What are the SavingsWhat are the Savings Today’s color changing uses about 3 – 5 liters of

coatings and about 2 – 3 liters of solvent Venjakob’s color change system uses about 500 – 1500

ml of coatings and about 500 1500 ml of solvent toml of coatings and about 500 – 1500 ml of solvent to make the same color change

Today, color changing can take about 5 minutes Venjakob’s color change system takes only between 30 –

45 seconds depending on coatings Di l t d d Disposal costs are reduced Higher productivity due to more hours available for

productionproduction


Financial AssumptionsFinancial Assumptions

Assume the following:Assume the following: 240 work days with only 15 color changes/dayCoatings cost = $20/gallon or $20/3 79Coatings cost = $20/gallon or $20/3.79

liter=$5.28/literSolvent cost = $10/gallon or $10/3.79Solvent cost $10/gallon or $10/3.79

liter=$2.63/literDisposal cost = $220/55 gal = $4.00/gal or p $ g $ g

$1.06 /liter Labor cost = $20/hour = $.33/minMachine Line cost = $200/hour=$3.33/min


Financial Summaryy

Coatings savings: 3.5 liters x $5.28 x15 = $277.20

Based on 15 changes per day

Solvent savings: Disposal savings: Labor savings:

1.5 liters x $2.63 x15 = $ 59.18 5.0 liters x $1.06 x15 = $ 79.50 4.25 min x $0.33 x15 = $ 21.04g

Machine availability improvement:

TOTAL SAVINGS/DAY

$ $ 4.25 min x $3.33 x15= $212.29

$649 21 / day TOTAL SAVINGS/DAY

Savings per year

$649.21 / day

g p y(240 days 1 shift):

Note: No belt recovery of overspray

$155,810


Additional Modern Methods to Reduce Coating Waste

Spray with fewer gunsSpray with fewer gunsSpray with 4 guns on a reciprocating

machine up to 30 feet per minutep p• Shorter lines to purge• Fewer guns to purge

Recover oversprayRemove the oversprayed coating from the p y g

recovery belt and reuse


Gun TechnologyWhen spraying at higher line speeds we recommend airless spray

Gun Technology

speeds, we recommend airless spray guns since very wide spray tips are available

Allows high speeds 5 – 10 m/min using only 4 guns with 18 inch wide tips that prevent “striping” problem

Very low cabin turbulence increases filter life and keeps cabin clean

For lower line speeds, air-assisted airless guns are used

Note: other automatic gun and pump technologies may be used


Overspray Recovery SavingsOverspray Recovery Savings

Manual spray transfer efficiency ≈ 30%Automated spray machine transferAutomated spray machine transfer

efficiency ≈ 60%Automated spray machine transferAutomated spray machine transfer

efficiency with recovery belt ≈ 80%


Overspray Recovery SavingsOverspray Recovery Savings

M l S N h fManual Spray = No chance for recoveryAutomated Spray machine = PossibleMachine equipped with recovery beltMust be a coating suitable for recoveryMust stay fluid long enough for recoveryProduction of a coating long enough to justify g g g j y

recovery


Recovery BeltRecovery Belt

Positives NegativesPositives

• Overspray beyond parts is deposited on belt

Negatives

• Water borne coatings dry fast, making recovery p

• Coatings can be reused immediatelyT f ffi i

g ydifficult

• Recovery system needs cleaning between color• Transfer efficiency

improves by 15 – 20%• Costs are reduced

cleaning between color changes

• Higher capital investment Costs are reduced g pneeded


Venjakob SystemVenjakob System

WINDOWS PC CONTOLLER

V BELT STAIN RECOVERY

BELT CLEANING UNIT

NOTE: V BELT AND CLEANING UNIT NOT IN WORKING POSITION


Reclaim Cross BeltV belt coatings recovery belt moves

Reclaim Cross Beltg y

perpendicular to conveyor

Belt rapidly removes coatings fromconveyor and transfers to receptacleconveyor and transfers to receptaclethrough a V-shaped scraper system

Water or solvent is automatically sprayed onto transverse belt to keep the belt continuously wet

V belt system is easily removed andV belt system is easily removed and replaced to allow complete changeoverof color if reclaiming overspray


Venjakob RecoveryVenjakob Recovery

High speed recovery cross belt removesHigh speed recovery cross belt removes coatings from primary recovery beltReduces length of time coating is on beltReduces length of time coating is on beltAllow recovery of even difficult waterborne

coatingscoat gsRecovery cross belt can be cleaned by the

operator during the automated machine’s p gcolor change cycle• Allows recovery for even short run jobs


Impact of Belt RecoveryImpact of Belt Recovery

On average 15 - 20% transfer efficiencyOn average 15 20% transfer efficiency improvement is anticipated with recovery of oversprayof oversprayIf run length is reasonable, coatings can be

recovered between color changesrecovered between color changesVenjakob’s recovery system makes it even

more practical to recover on shorter runsmore practical to recover on shorter runs


Quick Change RecoveryQuick Change RecoveryHigh speed belt g p

removes coating to recovery scraper

Scraper cleans coating from belt to container

Scraper is removed in 10 seconds

Spare scraper installedDirty scraper quickly

l d fflicleaned offline


Financial Impact-ExampleFinancial Impact Example1 mil coating covers 1604 ft²/gallon3.5 mils is an average coating wet

(sealer/topcoat)Therefore expect:Hand Spray = 137.4 ft²/gallony gSpray Machine w/o recovery = 275 ft²/gallonSpray Machine with recovery = 366 ft²/gallonp y y g


Financial Impact-ExampleFinancial Impact Example Average cabinet door = 3.2 ft² 2 sealer and 2 top coat passes = 12 8 ft² 2 sealer and 2 top coat passes = 12.8 ft Assume only 300 doors/shift or 3840 ft² to coat Hand spray = 3840/137.4 = 28 gal/shiftp y g Spray machine w/o recovery = 3840/275 =14 gal/shift Spray machine with recovery = 3840/366 = 10.5 gal/shift

Hand spray to Spray with recovery = 17.5 gal/shift• 17.5 X $20 = $350 / shift or $84,000 / year$ $ $ , y

Spray machine w/o recovery to Spray with recovery = 3.5 gal/shift• 3.5 X $20 = $70 / shift or $16,800 / year


Summary What are the GainsSummary…What are the GainsFaster color changes - between 30 – 45

dsecondsReduced loss of coatings and solventReduction in waste generation for disposalMore performance from machine and laborMore performance from machine and laborEnhances environmental Green initiativesL tLower costs


DemonstrationDemonstration• Venjakob “Perfect”

reciprocating sprayreciprocating spray machine

• 3 color changing• 3 color changing system (2 used for demo)demo)

• Not installed: Interval Air pressure Rinsing system


Demonstration – Coating System

Pigmented waterborne UV coating2 colorsOverspray recovery between colors p y y


Demonstration - ProcessDemonstration Process

Spray cabinet doorsOIR flash oven – 1 minuteO as o e uteConventional oven would be 5 minutes

High velocity/ IR jet oven – 2 minutesHigh velocity/ IR jet oven – 2 minutesSurround UV final cure oven


Questions before we leave?Questions before we leave?


Documents

Color Application, Changeover, and Recovery · reduce lost coatinggps and solvents…speeds up the process to 30 – 45 seconds depending on the coatings 2. Automatic controlled cycle