In the fast-paced world of industrial manufacturing, efficiency is critical to staying ahead. That's why we're excited to be working closely with a leading paint manufacturer and an end user on a groundbreaking project that promises to transform the way industrial equipment and containers are painted. The centrepiece of this development is a state-of-the-art 2-pack paint system, designed to significantly increase productivity, while reducing costs.
The Challenge: Speed, Efficiency, and Precision in Spray Painting.
The process of painting large industrial assets such as containers, agricultural machinery, storage units, and modular workforce welfare units has always been time-consuming and costly. In particular, the bottleneck in many facilities is the drying time for the paint. Traditional paint systems may take an hour or more to dry, during which time equipment sits idle, and spray booths are blocked, creating inefficiencies and increased overhead costs.
Additionally, traditional drying methods often require gas-powered heating systems to ensure paint cures correctly, especially in colder environments. This adds both expense and complexity to the painting process and its not great for the environment either.
The Game Changer: 2-Pack Paint with Catalyst
The materials manufacturer that we’ve been working with has developed a new, high-performance 2-pack paint that dries significantly faster - within just 10 minutes, even in cold environments. This rapid drying time eliminates the need for gas-powered heating systems, reducing energy consumption and saving a substantial amount of money.
The 2-pack system consists of two components that are mixed before application:
- A Primer with Catalyst
- A Topcoat with Catalyst
These paints feature a twin-basing inlet that ensures both components are mixed with the same catalyst, reducing complexity and ensuring consistency.
Industrial Impact: Increased Productivity and Reduced Costs.
For industrial manufacturers, the benefits of this new paint system are substantial:
- Increased throughput: The rapid drying time means less downtime between coats or applications, allowing more units to be painted in less time.
- Elimination of heating systems: No need for gas-powered dryers in cold environments, saving energy and cutting operating costs.
- Improved workflow: Spray booths can remain free of bottlenecks, further enhancing overall productivity.
The paint's quick drying nature is particularly beneficial when painting large items like agricultural machinery, containers, and modular units, which require consistent and durable finishes. By reducing the time spent in drying and curing stages, companies can meet tight deadlines and respond quickly to market demands.
Optimizing the Application: Viscosity, Atomization, and Pumping.
Achieving the perfect application of this paint requires precise attention to its viscosity and how it's mixed. Working closely with the paint manufacturer, we’ve tested various formulations to ensure the paint can be pumped smoothly and evenly, making the process as efficient as possible.
Key considerations include:
- Viscosity: We ensured the paint is “pump-friendly,” allowing it to flow efficiently through the pumping system without clogging.
- Atomization: Understanding the pressure at which the paint atomizes properly was essential. We worked out the exact pressures required to achieve the optimal spray pattern.
- Spray Tips and Pump Size: Different tip sizes affect the flow rate and atomization. By experimenting with various spray tips, we were able to match the right tip size to the correct pump size for maximum efficiency and finish quality.
Paint Trials with Graco Equipment
To ensure the paint performs as expected, we’re conducting pre-trials and live trials using Graco sprayers, which is known for its reliability and precision in industrial applications. These trials help refine the paint’s application parameters, such as mixing ratios, pump pressure, and tip sizes, ensuring a perfect spray every time.
Final trials are being conducted with our customer this month. The data and feedback gathered during these trials will be crucial for rolling out this paint solution to the broader market.
Conclusion: Trust and Collaboration for Optimal Results.
At the heart of this project is a strong collaboration between the paint manufacturer, equipment provider, Spray Plant UK and end users. Our expertise in optimizing spray systems combined with the paint manufacturer’s advanced materials ensures that this new 2-pack paint system is not only practical but also revolutionary in its ability to save time and reduce costs.
At spray plant, we’re not just a provider of Spray equipment and accessories, we’re experts and committed to help materials manufacture continue to deliver innovative materials to the market. We’re confident that this collaboration will result in a breakthrough solution for the industrial manufacturing sector.
Stay tuned for the full results of our trials, as we expect to deliver a game-changing advancement for the painting of industrial assets. Watch this space!