Problems faced in building a paint shop y y y y Air flow Compressed air Heat Electricity

Volume of air going across the booth 12000 cfm commercial booths«. U require a lot of power«« Paint booth exhaust: up the roof«« at the end of the building«.. Semi down draft paint booth: Up the roof- air intake filters«« at the end of the booth- air exhaust filters«.. Less expensive booth-- Cross transfer booth: Inlet and outlet both at the end of the booth«. Efficient use of shop floor space«« most economical of all the booths«.. Side down draft booth: Down Draft booth: Reverse flow spray booth: chance of contamination is greatly reduced«.. Infra cure booth: much like side down draft booth«« but infra lamps mounted on the side parts«.. Deluxe trucks booths: Open front paint booths: for painting parts«.. HOW TO MIX AUTO PAINT:::: Paint wont harden properly««.. It wont spray properly«« Not right viscosity to work in your gun««. Paint mixed with one type of thinner and hardener on top of that««. Sometimes mixed with reducer«.

Paint cup«. Tells the ratio of the paint and the thinner to be mixed««.

HOW TO SAND THE AUTOMOBILE BODY:::: Making the panel flat after primer to give a base for the top coat«. Don¶t use hands but use a block to sand the body«..

Price installation««.. Safety«« efficiency all play a vital role««.

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Ltd. To increase productivity. reduce cost of painting. Automatic Painting Machines are designed. Bahrain. developed in Japan.Automatic Painting System Autocoat Engineering (I) Pvt. Autocoat is now offering great opportunities to Indian manufacturers with such versatile Automatic Painting Machines An Automatic Painting System has a Painting Booth composed of a partition having side Walls. a Ceiling. Dubai. Saudi Arabia. Egypt etc. Taiwan & China and are extremely popular resulting competitive products. is already in manufacturing of painting plant on Turn Key Basis having supplied many large Spray Painting Booth & Conveyorised Phosphating & Painting plant all over India. and a Floor which jointly define .

a working space isolated by the partition from exterior space for accommodating a work piece to be painted in a position therein. The partition has air inlet and outlet ports opening into the working space.Less manpower cost.Less power .Less rejection y Lastly highly economical & reliable High volume Automatic Painting machines are very popular in China & vide rage of models are competively priced for good quality product. . .Less heating . A movable painting mechanism such as a Automatic Spray Gun is disposed adjacent to the work piece position and controlled by a control unit disposed outside of the Painting Booth and including a Drive source. The control unit and the movable painting mechanism are interconnected by an arm accommodated in an arm housing extending through the partition with a sealing member hermetically sealing a gap between the arm housing and the partition. paint consumption cost etc.Less space . A door is mounted on the partition in the vicinity of the work piece position for transfer of the work piece into and out of the painting booth Automatic Painting Machine should y y y y y y Eliminate skilled Painter or Operator Deliver consistent quality of painting on product Simple to operate High productivity of Paint consumption Finally cost per unit is lowest due to Be of International quality .

Before tieing up. Autocoat & Huan Yu had carried out detailed exercises so that our customer in India are benefited: y QUALITY PRODUCT in terms of life . TRAINING OF AUTOCOAT ENGINEERS AT M/S. Booth resistance to corrosion increases operator efficiency. making it applicable for a number of application. Huan Yu has been credited with the ³Certificate for Excellence´ in contract and credit. These products are completely imported. Automatic Painting Lines. Autocoat have tie up with ³HUAN YU". and other industries. y y . and leading manufacturer for Automatic Painting Machines. mainly small sized products. AVAILABILITY OF SPARES during life of equipment: Annual production capacity is 3000 sets. These machines can be added on with small air supply units and infrared and UV ovens. workmanship & standardisation M/s. ³Certified for Quality´ by the Guangzhou Municipal Board of Quality and Technology Supervision and the Guangzhou Municipal Bureau of Environmental Conservation. Portable Auto Painting Machine. HUAN YU. ISO 9001:2000 Certified. Depending upon the type of usage paint consumption and production capacity needed. The basic need for automatic painting machine is that the quality of painting can not be matched with manual spray painting. who inturn look after equipments and after ³Sales & Services´. and we stand in hand to hand with these products. Auto Spray Painting Line with out Robot. The automatic painting line can be availed in various sizes suitable for unique or standard application. QMS CE.Automatic Painting System Introduction Autocoat offer precision engineered range of Auto painting system widely used for the purpose of spray painting and immediate drying. tested as per international standards. an ISO 9001 Company. high production capacity can be achieved a comparatively less cost when compared with the painting practice in India.

y TO ANSWER EVERY TECHNICAL QUESTION from Customer in India without need of contacting with M/s. Fine Quality. and backed by Autocoat Technical Guidance & Expertise. The company combines the experience and technology of Taiwan and Japan and wins consistent favors from various customers by advanced technology and high quality. This company holds the tenet of ³High Efficiency. with its headquarter in Taiwan. The Auto Spray Painting Machine or the Auto Spray Painting line is suitable for Plastic. The company is located in Jiaoli Donghe Industrial Zone. Huanyu Automatic Machine Co. Good Faith´ Under outstanding researchcapability. scientific programming. Dongguan. Ltd.. Zhongtang Town. sports equipment. FRP. appliance.. Ltd dedicates itself in the research and development of various special machines to meet customers¶ demand on spray devices and in the design and production of various painting devices of high quality and productability applicable in the industries of plastic electronics. Since its establishment. ABS. etc that is we can also call this painting line as y Mobile Phone Painting Line .The products are imported. More about Huan Yu Company -: Dongguan Huanyu Automatic Machine Co. Company strive for making progress with you. hardware. (Taiwan ± funded) is a cooperative company of strategy and technology of Taiwan and Japan. after sales service and technical expertise. tested as per international standards. covering an area ofr 20000m2 . excellent technicians as well as outstanding processing technology and first-rank capability of development of engineers. holding an innovative concept and professional experience together with reformed technology. updated devices. Huan Yu. advanced technology and improved after service. vacuum plating etc. unless for major questions.

Plastic Electronics y Hardware y Sports Equipment y Household Appliances y Vacuum Coating Industries y Such as various types of high-yield.1 Fingerprint ID . Mixing Station y y y Mixing and storing paint materials in the open shop environment invite and practically guarantee faulty finishes. Investing in a dedicated mixing and clean area will save many hours of corrections later.1. 2. and how it and the practices used within help avoid dirt in the finish. high-yield high-quality automation can paint equipment. superior technology and processing engineers and development capabilities. the accumulated expertise. to develop all kinds of special models for our customers to be on the stringent requirements of spraying equipment.y y y y y y y y y y y y y y Toys Painting Line Helmet painting line Television painting line LCD Painting line Gift articles painting line Plastic painting line ABS painting line FRP painting line Clock Frame Painting line Shoes Painting Line Wheel Cover Painting Line Wooden door painting line Wooden frame painting line Automatic Plastic Painting Line Huan Hu believe in always uphold the concept of a breakthrough. we show details about this clean area. In this section. Widely applicable to the design and production of.

which pays off in big dollar savings. A microscope is a must ² this is your "dirt cam". We have instead found that practices used or not used in the shop. Once embedded. the contaminants they portray were visible to the naked eye as little specks or bumps on the surface or in the finish itself. Contaminants come from all quarters.1. "my booth isn't working. nothing short of actually stripping the finish can really remove the particles. the incredible clear depth of topcoats ² serve to also magnify contaminants trapped on the surface during the finishing process. which helps in tracking down the source. now they're terrible. control or suppress than others. 2.3 Investigative Tools During the investigation of suspected contaminants.Even though the images were magnified to make them easier to see. Today's finishes and clearcoats are more sophisticated than ever. it is critical to really see the nature of the contaminent. so it must be the booth. Although people tend to say. steps taken or ." Our experience has shown that it is almost never "the booth". Each contaminant has its own "signature"." what they're really saying is "my finishes used to be great. and the characteristics that enhance the paint finish ² the super-smooth finish. The presence of these contaminants in the finish usually requires that the finish undergo additional buffing and polishing to minimize their visibility ² known as "cut-and-buff" in the shop. Some are easier to manage. Keeping the "dirt" out of the finish in the first place through good practices and vigilance minimizes cut-and-buff. your window into the world of the nearly-invisible. The key is to do everything possible to make sure few particles make it to the surface finishing in progress.

You have to examine the evidence with magnification. you can literally take the microscope to the finish problem.1.1 The History of the Spray Booth .. Although we show a traditional laboratory microscope and camera setup. the quality of materials used. There really is no other way. 1.not taken to prepare the vehicle. then one must probe the clues left behind in order to solve finish problems. With the portability of a laptop. Image quality is excellent: in fact. inexpensive microscopes which send their images to a desktop or laptop computer are available today. If "the booth" really is the last suspect. etc. most of the 60x images for these pages were made using a famous-maker "toy" digital microscope plugged into an office laptop via USB. were really making all the difference in the finish.

When spray guns were first used on the assembly line. The new material proved virtually impossible to apply with a brush. Chicago's Marshall Field & Co department store. DuPont introduced nitrocellulose lacquer. The advantage of this unique new lacquer was its fast drying time that cut the finishing times down even more. In 1887 maintenance supervisor Joseph Binks invented a coldwater paint spraying machine to apply whitewash to the subbasement walls of his employer. The next year Civil War veteran Dr. The spray gun developed from those concepts as early as 1907. The road from these inventions more than a century ago to today's sophisticated finishing systems is a dramatic one. It was a timely idea since Henry Ford introduces his Model T the next year and mass production was just starting to evolve. Finishing operations could now be completed in just 3 days.The genesis of the spray booth came about through the effects of several inventions during the late 1800's. The spraying of paint was first used in the furniture industry. but it was discovered that spray guns could transfer the lacquer smoothly and quickly. Then. finishing times were slashed to just eight days. derived from a plentiful supply of World War I surplus gun cotton. and the spraying . Allen DeVilbiss invented the atomizer for medical use.

a revolutionary automotive achievement. Moreover. manufacturers and other employers must comply with strict regulations concerning worker safety and health. such as water wash. "Air wash" used to be the phrase that described what we know today as dry filter technology. there have been vast changes to what finishers can exhaust into the planet's air or other ecological systems. but all over the world. Spray booths and their systems have been critical to our hemisphere's development and defense for nearly a century.of paint replaced hand brushing.downdraft airflow and many others. Natural products filling the expanding needs of the finishing industry came after that first spray gun. They appear in every type of industry imaginable. How many other changes have there been? In these images one can see the awareness developing for finish quality improvement and other improvements as well. they found it to their advantage to design and build overspray collection systems integrated with their spray equipment. That in turn spawned technologies we now take for granted in spray booth design. usually for very specific industrial and automotive manufacturing applications. and their enhancement of the products produced has meant a higher quality of life for everyone . which we now know as spray booths. Detroit rapidly emerged as the largest single consumer of paint spray equipment. In order for the companies making spray application systems to sell their products. only a few of the old pictures show painters or applications specialists using respirators or other protection. For example. Today. like that shown on the right. including exhaust canopies. not only here.

manufacturers and others who include finishing as part of their process are finding that they must comply with new. The days of OEM finishes or refinish product applied in a "homemade" spray booth. more stringent rules. and an odor which proclaims that there are paint and coatings evaporating into the air? Is production time spent on re-dos due to dust or dirt contamination or uneven curing. are swiftly coming to an end all over the world. Competition centers on who can get what to the market with the least cost and highest profit. is there evidence everywhere of paint or coating overspray. Another driver is the never-ending quest for quality in production.1.2 Who Needs a Spray Booth? Is the finishing or refinishing operation in question clean and energy-efficient? Does it meet the business's production standards and levels? Or. .1. global warming and the prevention of atmospheric and other pollution on the agenda of every government. With concerns about greenhouse effect. or perhaps powder recovery or other technology. or none at all. or equally sophisticated water wash impingement. rather than meeting production timelines? Modern paint and coatings require spray booths with the right technology ² preengineered filtered heated air and precise temperature controls for all relative cycles.

Additionally. such as size and portability. How can products such as those offered by Global Finishing Solutions help? Equipment engineered specifically for isolating and enhancing finishing operations. A larger booth will cost more than a smaller booth. dual skin. is the solution. however. Global Finishing Solutions's . of a spray booth system is affected by the requirements of the object to be finished. as with single vs. the materials the booth itself is constructed of. These three factors together determine the investment required For example. and the type of airflow required to adequately power the process. only those who can achieve a high-grade finish on the first attempt will prosper. choices really do affect the quality of the finish. a few decisions have to be made. When the time comes to acquire a spray booth system for the first time. a fundamental requirement of fiscal prosperity. A crossdraft system will cost less than a pressurized or downdraft system. why spend money for the unneeded feature? When it comes to airflow. while at the same time complying with the myriad of requirements established relating to safety and health. How are these two influences impacting our world? It will work this way.Those refinishers and manufacturers who can reliably reach their quality standard on the first pass are the ones who will dominate their field. "Is a premium finish really required?" then becomes a critical question. The cost and ultimately. When the benefits of one choice versus another are negligible. Only those manufacturers or refinishers that can bring their processes in line with current regulatory demands in their region will continue to operate. the final configuration. equipment such as ours can help the manufacturer / refinisher achieve a superior finish in one pass. an non-insulated single skin configuration will cost less than a dual skin insulated model. And of those that continue to operate.

Our Equipment Features: Flexible modular design -Multiple width. Industrial and Truck / Heavy Duty Spray Booths provide a safe and efficient working environment for all coating applications. Today's technology combined with over 100 years of proven experience ensures a high-production facility with years of dependable service.Automotive. length and height combinations allows for expansion from 24' to unlimited lengths Pre-engineered heated air management systems -Downdraft -Pressurized Crossdraft -Crossdraft Quality construction .

S. Installation and Service distributors More choices to meet your requirements Wall designs -Single (non-insulated) -Double (insulated) Booth configurations -Drive-Thru -Split -Solid Back -Combinations -Curing ovens -Custom engineering for special applications -2-axis and 3-axis man lifts -Indoor/outdoor spray booth systems -Indoor/outdoor heated air makeup systems Who needs a spray booth? Virtually everyone who applies coatings of any kind.-18-gauge pre-coated and 14-16 gauge structural steel components -Precise tolerance engineering -Wall-mounted 6-tube ETL approved Class 1 Division 2 fluorescent light fixtures for superior illumination -Equipment installation by certified (S. and help prevent environmental pollution.) Sales. .I. Spray booths offer quality and efficiency.

Exhaust -Air Make-up .1. Provide a clean environment in which to paint. booths have several basic features in common: -Working Chamber.3 There are Four Critical Reasons to use a Spray Booth: Reason 1: Confine the application of a hazardous material to a restricted controlled environment Prevent hazardous overspray and volatiles from escaping confinement and causing fire or explosion to nearby operations.5. Control air fuel/mixture so that a combustible combination cannot occur.1.4.a How Booths Work -Intake -Accessories .1.a Components of Spray Booths Whether complicated or simple.1. Reason 2: Reason 3: Reason 4: .

4. and moving air. The force and direction of the air. 3. keeping airborne dust from entering cup. In a mix room. which can be filter pads or water.1 Mixing Area 1. 2. A thorough cleaning and blowing off outside the booth is mandatory. Tighten lids on partially used containers. 4. 7. 6. Place paint strainer directly over paint cup. Use only fine nylon or metal strainers. Moving air transports solids to filtration. but also the quality of the finish. Filtration media. a spray booth collects solids known as particulate emissions. with either human or robotic assistance. A spray gun or similar device. Prior to any spray operation. this suit must be completely free of all lint. use once and discard. 5. Replace spray gun cup strainer weekly. overspray and airborne contamination. 2. 9. the moving air stream also transports harmful and dangerous evaporants out of the working area.By design. are the primary tools in this collection. Prep workstations and mix room systems work in similar fashion. . or in a storage cabinet just outside the booth. Use only metal mixing sticks. 8. Store throwaway mixing cups in a dust±free container. Store painter's suit in clean. the efficiency of the filtration. filtered mix room. Provide a clean surface during all mixing of material. and the characteristics of the coating equipment ² these three elements ² determine not only the overall efficiency of the coating operation. Pressure rinse all spray guns with clean solvent (never wipe out interior of cup) and store with lid attached. The airstream moving through the booth gathers the solids and transports them to the filtration medium. minimizing worker injury and hazard of explosion. applies the coating material.

Leave the booth running in the paint mode while loading and unloading 2.2 Paint Spray Booth Close all doors.4. Keep booth operating in balanced spray mode when not in use.4. Remember. 2.3 The Process . for best results: 1. Replace compressed air hose to hanger when not in use. Change burner and floor filters on a regular schedule. Maintain uniform airflow across the entire length of grating. each vehicle.2. 3.

Use only the high quality lint-free towels available. 0. outside the spray booth. Paper and tape around repair area with 18´ high quality masking paper. Tack six feet of compressed air hose closest to gun connection and place on ho rack. ***OUTSIDE THE BOOTH*** 1. Close all doors. 5. ***INSIDE THE BOOTH*** 8. placing the paper over the plastic bag and tape paper to plastic. 2. load vehicle. 1 Blow-off repair area and paper with 40 psi. Repeat the chemical wash procedure. 2. 6. Use throw-away or reusable wheel covers. Tack repair area and 18" masking paper. 7. Needle must be set at balanced to remove 1. .We're assuming that the vehicle has been properly treated and repaired. you'll containing and confining the greatest sources of contamination to outside of the final refinish area. Chemical wash the repair surface. 9. Blow off with high pressure (100% of vehicle). 4. With spray booth operating in the paint mode. By following the steps below. 3. ready to brought into the spray booth for refinishing. Paper or plastic cover should not extend more than 6 inches below the vehicle Never cover any wheel well 100%. blow-off vehicle and masking paper with 40 psi. centered over gra front±to±back and side±to±side. 1 Observe spray booth balance gauge. 1 Bag vehicle. any airborne contamination during the spray mode. Blow-off with high pressure (100% of vehicle).

1 Prior to first coat of base. from the repair area. blow off and tack the paint suit inside the booth away 6. During this phase. blow off (40 psi) and tack the surface with a new tack rag. manufacturer instructions. never leave the spray booth enclosure. 2 In proper attire (a clean painter's suit). coats for proper coverage (only if mix room is not connected to spray booth). coats for proper coverage (only if mix room is not connected to spray booth). 1 Prior to applying the first coat of clear. . This flash of three minutes allows for the clear overspray to be removed from the cabin. the booth away from the repair area. 2 Apply additional coats of clear. 1 Tack repair area and masking paper with new OEM (or equal) tack rag. 2. apply first clear coat per paint 1. conditioning prior to painting. 4. 2 Prepare and store enough clear material in spray booth to complete the number of 0. 1 In proper attire (a clean painter's suit). instructions. 1 Prepare and store enough base material in spray booth to complete the number of 5. 8. 2 Allow the spray booth to flash at least three minutes before changing over to the 3. providing a clean atmosphere for curing. apply first base coat per paint manufacturer 7.1 Chemical±wipe surface and paper with pre±saturated wipers for optimum surface 3. blow off and tack the painter's suit inside 9. After the last coat of base has been applied and properly dried. Blow-off (40 psi) and tack repair area and masking paper between each base coat. cure cycle. 1 Apply additional coats of base as required.

Chemical wipe fibers left on or in doors.3. 3. Remember.5 Paint Mix Rooms . Low air movement around vehicle. hood or track joints Poor quality of tack rags and tacking techniques. Uneven velocity around vehicle.1 Top 10 Common Causes of Contamination #1 #2 #3 #4 $5 #6 #7 #8 #9 #10 Not understanding the importance of THE PROCESS when p vehicle. the spray booth must be operating in the spray cycle with only one set of entrance/exit doors open when unloading the vehicle. Poor quality of paint strainers. Poor surface preparation and inability to see contamination o prior to spraying. cycle before removing.3. . Poor maintenance of spray gun and gun cleaning procedures Booth balance (too positive/ too negative). Contamination of booth walls or floor.2 Allow the spray booth to cool down for a minimum of five minutes after the bake 4.

You can match thousands of factory colors. Your local jurisdiction will probably have codes regulating your paint mix room size. 3. and quart and gallon agitators. This option will help maintain a cleaner mix room environment and cleaner vehicle paint work. You should put your mixing machine and accessories in a pre-engineered paint mix room. Paint mix rooms are generally located next to the spray booth to maximize painter productivity. Your paint is ready when you need it.1 Sample Floor Layout in a Small Collision Facility . 2. It should have color-corrected artificial lighting and downdraft ventilation. 3. offer vestibule kits to enclose this area. Time savings.4. label printers. Some manufacturers offer exhaust-only models. A typical paint mix room is constructed of sheet-metal panels much like those used in spray booths. You mix only the amount of paint you need. Versatility. while other manufacturers may have both input and exhaust blowers. proximity of paint mix room door to the spray booth door and ventilation requirements. including Global Finishing Solutions. The input blower will pressurize the paint mix room to push airborne dust away from the door when it is opened. You will also need digital scale. Your paint supplier will help you choose the right equipment for your application. computer. Paint mix systems must be installed in a clean. well-ventilated room. Waste reduction.In-house paint mixing systems offer many benefits including: 1. Several suppliers. Paint mixing machines come in many different sizes.

2 Sample Floor Layout in a Large Collision Facility . The versatility of a prep station helps keep air clean and boosts productivity in a small space by allowing priming and parts jamming to take place outside the main booth.4. 4. 2. 3. 3. In this case: 1. can double as a final inspection and delivery area. kept clean and well lit.Even smaller shops can take advantage of good planning and modern equipment. A wall or partition separates the spray booth from the metal working area ² an effective substitute for the distance that might separate it in a large shop. Parking angles and drive widths are planned to make the best use of limited space. An estimate area.

Metalworking is located well away from the paint shop. so your spray booth can be kept free for assembled vehicles. Prep stations or limited finishing workstations located just before the spray booth improves the prepping operations' need to match factory paint finishes.The design you see here offers most of the features this guide recommends: 1. A floor-rail and dolly system lets you move cars sideways. so dirt and dust from sanding and grinding operations can¶t contaminate new paint jobs. The paint mixing room is located next to the spray booth for . 3. 4. They control dirt and let you do priming. 2. backward and forward without starting their engines or remounting their wheels.

and separated from it to comply with NFPA regulations. so he can easily track the parts status of each job. Clothing. 7. This is the best work to show off to your customers because it demonstrates your close attention to the finishing touches. 8. Detailing is right after the reassembly area. Cool down / unmasking / re-assembly take place just outside the spray booth. Parts storage is right next to the production manager¶s office. A vestibule between the two allows access to either the booth or mix room without being exposed to the shop environment. 5. Best Practice for the Paint Mixing Room Cut Shop Waste and Pollution Reduce Health and Safety Hazard Save Money Keep All Containers Covered Install a Ventilation System or Prefabricated Mixing Room Wear Air Purifying Respirators Wear Chemical-Resistant Gloves. 6. and Eye Protection . Final inspection/delivery area has easy access to a meeting room/office for final discussions on the outcome of a job.convenience.

Division 1 (explosive) environments.. By putting a lid on it you will keep harmful vapors out of the air that you and your co-workers breathe. install an exhaust hood behind the mixing table). A well-designed ventilation system will pull harmful vapors away from you and significantly improve air quality in the mixing room.Practice Waste Reduction Use An Automated Gun Cleaner Keep all Containers Covered An open container of paint or solvent contaminates the air and wastes money. common in many paint mixing rooms. A prefabricated mixing room has built-in ventilation. Prefab units come in a range of sizes and designs for convenient placement in the shop. To get the most protection from your ventilation. You'll also save materials and money by not letting your expensive paints and coatings evaporate away or be ruined by exposure to air. back to top | Automotive Refinishing Partnership . Remember: all electrical equipment in the paint mixing room (e. switches. ventilation fans. Be sure to set up equipment such that the ventilation draws vapors away from work stations. poses a serious health and safety risk..g. make sure you position vaporgenerating materials and equipment in front of or near an exhaust outlet (e.g. lights. telephones) should be approved for Class I. back to top | Automotive Refinishing Partnership Install a Ventilation System or Prefabricated Mixing Room Inadequate ventilation.

.134(d)(3)(iii). the respirator won't protect you! Your employer should have an implemented filter change schedule as specified in 29 CFR 1910. This respirator should provide adequate protection for typical mixing room tasks. always use an air-purifying respirator with organic vapor cartridges.Wear Air-Purifying Respirators Vapor-generating materials and equipment pack most paint mixing rooms. you must: (1) Make sure it forms a tight seal on your face (a clean shave where the mask touches your face is step one. but can pass through your skin and damage your body's internal organs. followed by a "fit test" from a safety professional). Remember: for a tight-fitting air-purifying respirator to work properly. Clothing. as specified by the manufacturer²once vapors saturate the cartridges. and Eye Protection Your skin and eyes also need protection from hazardous paint materials. Many chemicals in coatings and solvents are not only strong irritants. When working in the mixing room. back to top | Automotive Refinishing Partnership Wear Chemical-Resistant Gloves. and (2) Change the cartridges on a regular schedule. Be aware of the variety of chemicals you use in the mixing room and choose chemical-resistant gloves and paint suits that offer adequate protection. A painter in a respirator is much less likely to breathe the harmful vapors in paints and solvents.

recommended for all painting tasks (and required by law in certain areas). The respirator or goggles/face shield will keep strongly irritating and toxic chemicals from splashing in your eyes and face²and keep you from mistakenly rubbing your eyes with a contaminated hand. transfer paint much more efficiently than conventional . Remember: even a more protective glove has a limited life span. An eye wash station is a must for any auto refinishing shop. in lower waste removal costs. Mix only the amount of paints and coatings you need. more efficient use of paints and solvents lets you save twice: up-front. High-volume. latex does not.For gloves. the hardening component in most clear coats. Warning: Isocyanates. and on the back end. especially if you use it when handling certain strong solvents²so. are strong skin and lung irritants² and the leading cause of occupational asthma. In fact. however. nitrile or butyl rubber make the grade. Recent studies indicate that skin contact with isocyanates may trigger an allergic reaction in your lungs. back to top | Automotive Refinishing Partnership Practice Waste Reduction Shops that reduce waste do something good for the environment and their bottom line. always follow the manufacturer's recommended change schedule and never use a torn or punctured glove. goggles or a face shield should be worn with a halfmask respirator (as described above). And don't overlook your eyes! A full face piece respirator will provide eye protection. on the amount of materials you need per refinish job. lowpressure (HVLP) spray guns.

pre-clean the gun cup to remove gross coating contamination. . Another good practice is to store and reuse left-over primers and basecoats. back to top | Automotive Refinishing Partnership Use An Automated Gun Cleaner An automated gun cleaner also saves you money²and improves health and safety in your shop. This practice extends the service life and effectiveness of the cleaning solvent used in the automated cleaning unit How Clean Are Paint Shop Cleanrooms? Although great strides have been made in paint shop cleanrooms. offered free by many paint companies.guns. These devices help you get the most mileage from your cleaning solvent. Before placing a used spray gun in the gun cleaner. make it easier to mix smaller quantities of paint and to track and reuse any left-overs. Remember: if equipped with an exhaust fan. By S. reduce shop waste. Select a model with a lid that covers the entire basin. there are still major opportunities to improve their cleanliness. make sure you frequently inspect and maintain the unit²leaking hoses and lids with a poor fit can contaminate your mixing room with harmful solvent vapors. Computer mixing systems. Thomas Boyce and Jan Pitzer Hosco Livonia. and minimize your contact with hazardous solvents. MI . Regardless of the type of gun cleaner you select. make sure the basin is equipped with an exhaust fan to collect vapors before they escape into the room air. especially with improvements in the design and construction of the paint circulation and supply systems . the result: you use²and need to mix²far less paint. . the gun cleaner should only be used when the fan is connected to an exhaust outlet that removes the vapors from the room. If you select a model that allows manual pre-cleaning in an open basin.

by eliminating dirt contamination and the resulting defects. cotton fibers and other pollutants carried by workers. hair. These steps are designed to remove contaminants that can cause flaws in the paint finish. dandruff. anyone entering a cleanroom must wear lint-free coveralls and a hair Figure 1 bonnet as well as pass through an air shower compartment that may contain a shoe scrubber. all of which can contribute to a greater potential for introducing dirt into the paint circulation system. expensive repair procedures can be avoided. which affect the quality of their work. Until recently. The main reason for cleanrooms is to improve the quality of the paint finish by reducing sources of dirt contamination on a wet film.During the past 15 years. what about the other 40% of dirt sources. Early evaluation of the sources of paint defects indicated that 60% of these defects were caused by dust particles. Along with the development of new coatings. most new facilities have incorporated cleanroom environments in which these materials are applied. This dirt contamination causes some manufacturers to repaint the entire car rather than making spot or panel repairs. But. powder. There is also a psychological benefit to this procedure because it conditions people to be aware of all sources of dirt and to think about their surroundings. lint. such as agglomerated paint particles. the automotive industry has developed a significant number of paint technologies to address the needs of the environment. They are more prone to shear degradation. . product appearance and durability. foaming and skimming. color carry over during the color change process and paint line cleaning? The newer high-solids and waterborne basecoat materials are much less forgiving than the older low-solids solvent-borne paints. agglomeration. supervisory personnel and visitors working around the paint shop (see Figure 1). But. most of the emphasis on eliminating dirt contamination in cleanrooms has been focused on the people working in the paint shop. Therefore.

There are also some exterior configurations of paint hoses that can be improved to reduce the flaking off of dry overspray. filling have greatly improved the overall operation of the paint supply system. fluid quick disconnect and stem. Within the interior of the piping system network there are many areas that are often overlooked as potential dirt traps. lowering the potential for dirt to enter the paint supply system. low shear regulators and new mix tank designs with liquid level controls and automatic Figure 2 . low shear agitation methods. The detail of one drop station is displayed showing a manual spray gun with connecting fittings and hoses. that eventually carries paint back to the paint mix room. An automotive plant could have as many as 50-80 spray stations depending on the length and number of spray booths. mini-filter. The size of the supply pipe could be 1. a main supply pipe exits the paint mix room and winds around one booth with four spray stations.5 inches depending on the plant. fluid control. Figure 2 shows a typical circulating-to-gun paint circulation system found in many automotive plants. the choice of the proper grades of stainless steel and passivated systems has reduced or eliminated the gelling of paint caused by metal ions. In addition. Figure 3 . which can be carried by airflows in the spray booth to the surface of the vehicle creating a defect. The development of lower shear pumps. While there are some continuing refinements of the storage and pumping supply systems. cavities or dead rooms where paint particles can collect and eventually lead to a contaminated finish. The first station of a circulating-to-gun system includes a return piping network.0-2. most of the emphasis on the management of dirt has shifted in recent years to the piping system. In this example. much of the work in paint circulation systems during the past 10 years has been focused on the paint mix room. which each subsequent station feeds.From an equipment standpoint. There are many variations of this basic system depending on the OEM customer and geographic location.

This bearing cavity completely encapsulates the ball so that no paint can accumulate in the interface between the ball and the polymeric body of the valve. When the ball is rotated some of the sticky or agglomerated paint particles can break free. The preference in new paint shops is for valves that incorporate an encapsulated ball (see Figure 4).Spray Station Ball Valves Normally four ball valves are used per color (two for supply and two for return) at each spray station. These valves are available in a variety of configurations. flow downstream to the applicator and create a defect. In these valves. Paint collects between the Teflon lifesaver seals and the interior of the valve body (see Figure 3). Many ball valves used for spray station drops are not specifically designed for paint and contain medium to large size cavities around the ball that can trap paint from previous or existing colors. There Figure 4 are no crevices or threads to collect paint or dirt where it can harden and later contaminate paint jobs. The last important consideration regarding valves is to closely match the bore of the valve with the inside diameter of the station drop to prevent any restriction or pressure drop in the system. the valve seats are placed on opposite sides of the ball and axially pressed together to form a substantially void free axial seal. The booth wall mounted valves can be either bulkhead mounted or reverse bulkhead mounted depending on whether the customer prefers valve handles inside or outside the spray booth. These areas are difficult. if not impossible. This valve also flushes cleanly during color change or pigging. The most common stainless steel tubing connection is the compression . compression fitted or tube stub. to clean during flushing or color change processes and represent one of the more significant sources of dirt in a paint system. Generally automatic station valves are mounted outside the booth for safety reasons to facilitate valve closing without interfering with the automation equipment. including threaded. Transition Connections Several types of transition connections are typically used in paint circulation systems.

those fittings can¶t be reused in another area. This type of connection has several advantages: 1. The next most common type of connection in a paint circulation system is the ball and cone style connection (see Figure 6). This connection is made using a ferrule and nut mechanical type seal (see Figure 5). 3. The connection has a smooth internal bore diameter if the correct tubing wall thickness is used. The design incorporates a 30-degree male seat on the side with the swivel nut and a 30-degree female seat on the other side of the connection. regulator and gun connections and around filters and gages with sizes of 0.375 inch. color changer. These are available in NPS (National Pipe Straight) or BSP (British Straight Pipe). The elimination of internal shelf areas or 2. Figure 5 The primary drawback of compression fittings is that once the tubing is connected. color changer or bulkhead Figure 6 . dead spots also helps maintain uniform fluid velocity and laminar flow in straight fitting configurations. much like a JIC or a pipe union connection.Ball area. These connections are most generally applied inside the spray booth for hose. 2. eliminating internal shelf areas or dead spots. and Cone Design 4. The smooth bore also maintains uniform fluid velocity and laminar flow in straight fitting configurations. The connection normally has a smooth bore internal diameter if the correct tubing wall thickness is used.style connection. The connections can be disassembled for maintenance without significant effort or damage. The connections can be broken for maintenance or rearrangement reasons without significant effort or damage. . This type of connection has two main advantages: 1. Ball and cone connections can be rotated and precisely positioned for neat and clean bundling of the paint hoses into and away from the applicator.25 and 0.

25. There is probably only one advantage to this connection type ± it is readily available and well understood from an installation point of view. The connection can be reused many times. In addition. which damages the threads and makes each mating component unusable for rearrangement or system modification.and 0. internal threads on female connections are exposed and provide many cracks and crevices for the paint to accumulate. gage and filter joints. especially with stainless steel. Another type of connection is NPT (National Pipe Tapered) or BSPT (British Tapered). which is a major dirt contributor in paint systems (see Figure 7). to have precise locations of ball valve handles or to Figure 7 . the tapered thread of the fitting will become tight and stop rotating at various and random angles. There are no known drawbacks of this connection type other than it is normally restricted to 0. is the recent application of sanitary clamp style fittings. If right-angle hose fittings are used. 2. Its benefits and drawbacks are identical to the compression style fittings. During assembly of components. The sanitary clamp style is used around mix tanks. Connections 3. Also. Last. NPT has three major drawbacks: 1. with stainless steel connections there is a tendency for the two mating surfaces to gall. Many of these connections have been eliminated in paint circulation systems except at pump. pump and filter areas and in overhead piping mains.5. These fittings are generally applied around larger line sizes like the compression fittings mentioned earlier. making rearrangement inexpensive and quick. This is a problem particularly when the installer is working to make racks of lines appear uniform. It is the only welded fitting listed here. particular attention should be paid to the internal construction. Color Changer and Automation Equipment Cavity-Free Connections . The assembly of NPT components leaves many internal steps or shelves at the connection area.Hose mount areas around color changers. Many 90degree fittings have a large dirt pocket in the back of the fitting.375-inch connections.

between the end of the fitting and the base of the manifold. This is a major new area of improvement in fittings because circulating systems¶ operating . The resulting challenge for paint fitting manufacturers is to provide accessible connection points to machines and color changers within smaller areas and to increase line sizes to provide higher flow rates and reduce pressure loss and shear. This allows precise racking or routing of circulation hoses away from the color changer in a neat bundle. 45 or 30 degrees or straight depending on the application requirements. Smooth bore provides consistent fluid stream velocity and eliminates internal steps or shelves where paint can agglomerate. connectors and fittings used for the supply and return circulation lines to color changers should be smooth bore. Laminar flow requirements can eliminate abrupt flow path changes in small fittings that can degrade paint color or luster and can reduce pressure drop at the color changer. installer and owner to consider the pros and cons of connector types during the specification development and decision making of the project. some new practices are important to consider. O-rings or Teflon wafers should be used to eliminate these traps and keep the assembly drive cavity free. since the swivel nut on the NPS (F) hose connector Figure 8 can be positioned at any angle (see Figure 8). Automatic stations are becoming more compact and smaller due to the limited space inside machines and robots to mount color changers and route paint hoses. Cavity free specifies that there be no machining steps or pockets (such as drill point pockets. which can occur in angle fittings) on the interior of the fitting body. In response to these challenges. it is increasingly important for the equipment builder. Every effort should be made to closely match internal bores between connecting components. 2. Paint inlet and outlet points of color changers should remain NPT or BSPT by NSP (M) straight fittings. Hoses. 1. These fittings can be 90. or dirt trap. One potential pitfall of NPT connections to color change manifolds is the gap.With the increased use of automation for paint application. 60. sweep-type fittings that facilitate laminar flow (see figure 9).

Fitting and hose selection for color changer outlets to the applicator has an even more critical performance requirement to ensure Figure 9 optimized color change time. minimize solvent and air use and eliminate color carry-over from one color to the next. Specifying tubing instead of paint hose.3. Hose Management and Containment Proper hose management and containment can have a significant impact on defect-free paint finishes and minimizing reprocessing. which requires a two-hose arrangement to the spray gun or color changer. It is important to keep in mind that paint hose is specified by its ID since it is critical to maintain paint circulation velocity within the recommended range by the material suppliers. difficulty maintaining viscosity or paint temperature or formation and discharge of dirt from the system onto filters or parts being sprayed. One hose supplies the station and the other hose returns the paint to the circulation loop. plastic tubing is specified by its OD to work properly with push-lok or compression style fittings. Conversely. while it seems a minor point. pressures are usually driven by the automatic stations and then color change time constraints. 4. can create significant circulation problems that will eventually show up in problems with fluid delivery to the applicators. One important consideration is the use of FEP or PTFE Teflon as the hose material between the color changer and applicator to further improve performance. Automotive paint circulating systems generally circulate to the gun. Any reduction in pressure loss within these stations provides direct benefit to the higher amounts of maintenance and expense related to seals and energy consumption. .

hose containment and hose life (see Figure 11). . minimizing overspray buildup between the two hoses. compact and low profile along the outside diameter of the hose. tape or wrap to hold the hose set. However. Bundled hose includes paint lines and pneumatic signal and trigger lines wrapped with a smooth. They provide a better snag-free alternative to ty-wraps and are much better than tape. the wraps have a tendency to snag on the booth grates and create motion difficulty for manual spray operators. It has just one hose surface. Figure 11 For both robotic and bell automation zones.There are several methods of cinching twin hoses together that are practiced in the industry (see Figure 10). with no crevices or recesses for housekeeping. Plastic nylon clips are more compatible with paints and solvents. which is objectionable to some spray operators. the tape gets sticky when exposed to solvent and picks up overspray. Some plants simply use masking tape to join hoses together. Bonded twin line hose is either continuously or intermittently bonded along its length. However. solvent-resistant exterior cover. This method is more maintenance free than tape. This design eliminates the need for clips. the bond seam along the hose creates a continuous crevice that is difficult to clean. Metal spring steel clips are small. They are nonconductive for safe use in electrostatic zones. Figure 10 Another approach uses nylon ty-wraps as a substitution for tape. Monoline coaxial paint hose assemblies (hose within a hose) built in lengths up to 25 ft accomplish the same improvements as the bonded twin line hose. The clip design also separates the hose surface to facilitate full hose surface cleaning. However. bundled hose with an exterior smooth cover provides excellent performance with regard to housekeeping. with one big advantage. Bonded hose also increases the structural rigidity. Eventually the dry overspray particles break free. It is also the most aesthetically pleasing and one of the most ergonomically superior hose assemblies for use in manual stations. become airborne and get carried to the painted surface creating a defect.

000 ft. improved first run capability and reduced repair warranty. dirt-in-paint or hose kinking and containment problems using this new technology. Virtually any existing hose or tube size and material of construction can be assembled into a bundle to solve housekeeping. Ergonomics has also been a driver of new product developments to reduce fatigue for spray operators. . check-valve-style stems and mini-filters mounted on the spray gun are all examples of advancing technology in manual spray zones (see Figure 12). Some automotive manufacturers have even created dirt-in-paint groups within their corporate paint engineering operations and are encouraging each plant to develop an ombudsman for dirt-in-paint reduction. Manual Spray Station Accessories Improvements in the design of manual spray gun accessory equipment have significantly contributed to reducing defects and reprocessing. Figure 12 With the variety of fittings and valves available in the market. Some users of these systems have adopted color-coded pneumatic lines to facilitate quick maintenance response in diagnosing station performance problems. Spray gun flow restrictors and quick disconnects are now available in durable composite materials that are 50% lighter and fully compatible with automotive paints and solvents.Advancements in extrusion capabilities and new economies of scale have enabled some suppliers to custom engineer bundled hose in quantities as low as 1. No-spit paint quick disconnects. The benefits are enormous and include reduced dirt-in-paint defects. Those automotive manufacturers who are committed to advancing the state-of-the-art cleanroom environments in new facilities have made improving the quality of their paint supply systems a priority. OEM companies must take a more aggressive role in requiring turnkey systems integrators and designers to use cavity-free products designed specifically for paint. Dirt-in-paint reduction is a continuous improvement process.