Paint booths and spray systems are often a production bottleneck in industrial operations. Labor issues are one cause of that, as the dirty, difficult and noisy work makes recruitment difficult. Painters are becoming hard to find and harder to keep, and high turnaround means lost knowledge within your shop.
It makes sense that many operations are turning to automation to minimize workforce risks in their industrial finishing systems. But technology has also become a driver of automation, not only as a path to reducing or eliminating bottlenecks but to improving results.
In his presentation at Spray Equipment & Service Center’s Tech Days, “Automation for your Complete Finishing System,” Blake Erickson of Graco said other drivers of automation include:
Overall equipment efficiency, such as increased uptime, performance, and quality
Data-driven manufacturing, which impacts not only product quality and output but predictive maintenance
Increasing demands, as clients are using more color palettes, which adds to inventory and leads to frequent color changes, and can impact lead times
Robotic costs are going down, citing a Stanford Institute study in which the median price of robotic arms dropped about 40 percent from 2017 to 2022.
Manufacturers of all sizes are benefiting from finishing system-related automation. Erickson cited four areas to target for automation that easily integrate with robots and reciprocators.
1. Supply: Efficiency Improvements Begin at the Source
With many manual systems, your staff might need an hour of labor to get set up and started. Automation eliminates much of that time. If your crew is not disciplined about shutdown procedures and cleaning equipment, you may have even more time to gain.
Consider these areas for automation related to material supply:
Electric pumps: Electric pumps are a good starting place because they become more efficient as power and flow rates go up. For example, Graco electric paint circulation and supply pumps are up to 80 percent more efficient than comparable pneumatic pumps. They also provide great energy savings, can be controlled remotely, and provide a log of activities.
Smart paint mix room systems: For example, the Graco Intelligent Paint Kitchen includes a smart set of sensors, actuators, and control modules, which provide improved overall control, tank control, and pump control.
Back pressure regulator: While traditional BPRs manage pressure on the circulation line, their sharp-cornered geometry can cause faster shear in metallic paint. The gentler design of new low-shear BPRs slow shearing effects to maintain the shine of the paint longer.
2. Electronic Proportioning: Savings, Efficiency and Versatility
Two and three-component electronic proportioning systems will save time and money vs. hand-mixing paint. They are easily integrated into PLCs for fast setup and efficient process control. They offer scalability with varying levels of benefits at different price points, but each features:
Fast color change
Minimizing waste
Material usage tracking and reporting
Ratio assurance for consistent flow rate and improved product quality
For example, can you mix paint closer to the gun? If you are mixing paint 100 feet away from the gun, you are wasting paint every time you change colors or finish a shift. If a company is doing many color changes a day, using an electronic proportioner can help eliminate the bottleneck from flushing lines, and save money on paint and flush solvent.
3. Atomizers: There is an Automatic Version for Every Manual Version
The investments in rotary atomizers and electrostatic spray guns often achieve 30-percent savings in transfer efficiency, which means less paint goes to waste and you achieve significant cost savings. Triggers, air and paint pressures, and electrostatics can be easily integrated into a robot or PLC for single-point control and accessibility.
A rotary atomizer improves quality, transfer efficiency, and cleanliness while spraying with robots, reciprocators, or on a fixed mount. The digitally connected atomizers are equipped with sensors to enable real-time, smart diagnostics and precise paint control.
Likewise, electrostatic spray guns increase finish quality and paint coverage, while decreasing VOCs (volatile organic compounds) and HAPs (hazardous air pollutants).
4. Robots: Consistent Coverage and Usage Improves Quality Assurance
Robotic painting devices eliminate variables among different manual painters. This makes for consistent coverage and paint usage and improves quality assurance. Simple robots also are emerging for High Mix, Low Volume applications. They are autonomous and easier to program.
Keep in mind that many components, spray guns, and mixing stations easily integrate with robots and reciprocators. Manufacturers of all sizes are benefiting from automation and robotics.
Work With Spray Equipment & Service Center for Your Automation Needs
Paint line automation in your industrial finishing system can help you:
Achieve high transfer efficiency and lower operating costs by reducing material waste by up to 30 percent
Reduce labor costs while dramatically improving quality, reducing scrap and rework due to operator error
Protect employees from dangerous conditions and repetitive tasks while lowering the amount of paint sprayed, VOCs, and waste disposal
What return on investment can you expect from paint line automation? Calculate your savings through Graco’s online tool, or better yet contact experts at Spray Equipment & Service Center for a consultation. We can work with you across the spectrum of automation. We also provide qualified technical support and added value through:
ADVICE: Our experience, expertise, and approach work for you at every stage of your business.
SUPPLY: We have the right equipment and parts in stock when you need them.
SERVICE: We are just a phone call away (866-953-0526).