The integrity of protective coatings relies heavily on good chemistry. That’s why an independent finisher of agriculture and construction equipment was looking for better ways to keep precise component ratios in the solvent-borne urethane paint used to coat large agricultural and construction equipment.
The shop’s painters did their best to hand mix the right combination of resin, catalyst and solvent for each job. But they couldn’t afford to run short on paint; so at least one gallon went to waste in the pressure pot. At $75 to $100 per gallon, costs quickly added up.
As material approached the end of its pot life, it would thicken and not flow well, causing poor paint spray. This was especially a problem during lengthy jobs, such as coating a large grain trailer.
To prevent runs/drips and get adequate coverage with a certain color, the shop’s painters had to mix in less solvent. The different component ratio made job preparation and cleanup inconvenient and time-consuming.
The finishing operation moved from manually mixing five to 15 gallons at a time in a pressure pot to using three-component positive displacement (PD) technology.
Working with their local distributor and Graco representatives, painters integrated the Pro Xs Electrostatic Spray Guns they already were using into a ProMix PD3K system.
- Three PD pumps supply components – resin, catalyst and reducing solvent – on ratio within 1 percent accuracy.
- Mix manifolds combine the components near the gun, not in a pressure pot. Mixing only what’s needed for each job significantly reduces cleanup time, solvent use, and wasted paint.
The result was impressive to the finishing operation. The finisher used to write a monthly check for $22,000 to cover coating costs, but that check shrunk to no more than $15,000 after their ProMix PD3K installation. With an annual savings of at least $84,000, the new three-component positive displacement system should pay for itself in less than two years.
For multiple electrical transformer boxes, the pressure pot mix amount was 5 gallons, and the PD3K mix amount was 2-2.5 gallons, resulting in a 40%-50% savings. On a 36-foot trailer, the pressure pot mix amount was 8 gallons, and the PD3K mix amount was 65 gallons, resulting in a 19% savings.
Painters are noticing a better finish quality through the entire paint job. They no longer need to compensate for poor paint flow toward the end of long jobs. Since the material viscosity is more consistent and the droplet size smaller, paint spray penetrates corners and other areas they couldn’t easily cover before.
Better yet, a top customer noticed a considerable improvement in the finish of their trailers. Such quality improvements have secured business for years to come
For more information, contact Graco at 1-800-533-9655, or visit www.graco.com/ProMixPD3K.
