Much as digital connectivity has transformed the industrial and construction sectors, you can now equip your rig with a smart spray foam system. The drum-to-gun spray technology will help optimize your spray operation and improve profitability by:
Eliminating ratio issues
Improving yield
Delivering quality results
The benefit of a smart system is improved communication and control among the proportioner, transfer pumps, and heated hoses. Alerts, flow meters and automatic shut offs provide assurance to the operators that the system is operating properly. Graco’s Reactor 3 proportioner is designed to simplify the operator’s job while getting the most out of the equipment. Its biggest selling point is that it eliminates the two largest causes of off-ratio issues:
Air in the fluid stream
Improperly feeding the Reactor with material
The system has additional features, including the Pro-Connect on the electric transfer pumps that enables switching between drums in as little as 30 seconds.
How the Smart System Works
The Graco Reactor 3 System is the most advanced spray foam and polyurea system. The key elements of the full system and highlights of their benefits, are:
Katalyst software
The application intelligence is what allows you to stay on-ratio throughout the operation. In essence, this is what makes it a smart system.
Reactor 3 Elite proportioner
The compact design reduces its footprint to provide additional room in your rig, and better protects the flow meters and hose connections from being damaged. Its new features include:
A touchscreen interface for intuitive operation and navigation
Redesigned inlet filters for improved serviceability
A new active ISO lube pumps to reduce maintenance
Reactor Connect
This app provides control of the Reactor from the sprayer locations and remote monitoring for managers. Its features include:
Remote control of the machine
Monitoring and troubleshooting with real-time dashboards
Streamline business decisions based on reports and data analytics
ProConnect
This technology improves changeovers and rebuilds so you can reduce waste and finish jobs faster.
Easier hookup drastically reduces time for drum changes
Easily move your pump in low ceiling height rigs
Makes pump rebuilds fast and easy by simply changing out the pump lower
Core E1 Transfer Pumps
Electric pumps are designed to optimize material supply and minimize downtime. They also use less energy to operate and are quieter than air-operated pumps. Among their many advantages, they:
Automatically shut down when out of material before damage occurs, including air entering the system which can compromise ratio
Communicates with the Reactor to optimize the material feed pressure
Xcelerator Heated Hoses
These robustly built hoses have longer life and warm up fast with internal or external heating options. Other benefits include:
Fully-independent A and B temperature control
Minimizes fluid and electrical connections
Better balance viscosity to improve mixing
Independent temperature control allows for Auto Pressure balancing to optimize yield
Questions to Ask Before Investing in a Smart Spray Foam System
A smart spray foam system is a significant investment, so be sure to do your research to make sure the scale of your operation warrants the costs. Some questions to ask:
How quickly can the ROI be achieved?
The answer will vary depending on your operation, but consider these direct and indirect benefits:
Even a 5% yield improvement can mean big savings. Use this ROI calculator to determine your possible annual savings (Cost per set X sets per year X yield improvement). In the example below, the company sees annual savings of $37,500 with a 5% yield improvement.
Your costs in the field from ratio issues will go down, as will the frequency of those events.
With an electric pump, you might be able to reduce the compressor size.
If you are able to reduce the compressor size, you might be able to reduce the generator size.
Do I need to buy the entire platform?
To realize the full benefits of the Katalyst intelligence, yes, you do need all of the elements. But, you do not need a full system to achieve significant benefits. The Reactor 3 platform has three levels – standard, pro and elite. You can get started with a standard proportioner and combine it with a Core E1 electric transfer pump to realize improved ratio performance.
Can we build a smart system over time?
Yes, upgrading the Reactor 3 platform from Standard to Pro will provide real time data, Reactor Connect capability, and advanced software with pressure balancing and power management.
The Pro model hardware can be upgraded to Elite level to provide additional intelligence, flow meters, and monitoring capability.
Why You Should Consider a Smart Spray Foam System From Spray Equipment & Service Center
A smart spray foam system can provide you with the best possible results every time. We can help you determine the right solution for your spray foam system. We also provide qualified technical support after the purchase and provide added value through:
Advice: Our experience, expertise and approach work for you at every stage
Supply: We have the right equipment and parts
Service: We are just a phone call away (866-953-0526).