Every single manufacturing company needs to reduce costs in industrial finishing on a daily basis. Now, when it comes to figuring out ways to do that, many resort to the simplest: applying less coatings or applying lower quality coatings. The downturn of that is that quality might be compromised.
The equipment used for industrial finishing
Depending on the size and type of manufacturing plant, the following equipment might be present. Also, according to the production capacity, more units of equipment should be put in place. In each case, the specific equipment you get might mean savings or problems for your industrial finishing operation.
For that reason, in this article we are going to consider 7 ways to reduce costs in industrial finishing by using the right equipment. Now, to get started, let us first overview the most used equipment for industrial finishing.
Manual spray guns
Manual spray guns are handheld tools used to apply paints, coatings, and finishes by manually spraying them onto surfaces. There are several types of manual spray guns, conventional, HVLP, LVLP, airless, air-assisted airless, electrostatic, and more.
They can be gravity, suction or pressure fed, the latter being the most common in industrial finishing operations. The coating is fed through a hose from a tank. Compressed air mixes with the paint at the nozzle to atomize it into a fine spray pattern. The operators can adjust coating volumes, air pressures, fan widths, and spray patterns.
In almost every industrial finishing plant, even those with high production levels, manual spray guns are commonly used to apply coatings like paints, varnishes, and other protective finishes to manufactured products.
Reasons to use manual spray guns
Versatility: Manual spray guns allow application of coatings to a wide variety of products. Workers can access and coat complex geometries.
Touch-ups, details and repairs: Manual spray guns enable localized touch-up of flaws or damage to coatings. Follow-up coating layers or repairs are often completed with manual spraying. Intricate parts or designs often require the control of a skilled painter with a manual spray gun.
Portability and multiple angles: Manual spray guns are brought to the part and moved around it for complete coverage. Operators can orient manual spray guns at optimal angles to coat hard-to-reach areas of parts. Manual spray positions can be adapted to maintain comfortable operator postures.
Prototyping: During new product development, manual guns allow application of coatings on prototype parts for evaluation. New coatings can be tested and qualified using manual spray before scaling up. For short run or custom coating jobs, manual spraying may be preferred over setting up automated equipment.
While it is true that manual spray guns fill an important niche in industrial finishing and maintain flexibility in applying coatings, they also require skill and are less consistent than automation.
Automatic spray guns
Automatic spray guns are mechanized systems that apply coatings without direct human involvement. The operation is automated, so, flows, and positioning are controlled programmatically without manual triggering.
Usually, automatic guns are integrated into larger finishing systems like robots or reciprocators. The most common types are rotary atomizers, electrostatic guns, high rotation bells, flow coaters, and jet nozzles.
Reasons to use automatic spray guns
Uniformity and efficiency: The coatings are applied with a very high degree of repeatability and uniformity. The controllers can be adjusted to spray based on presets to maximize transfer efficiency. Precision automated spray control results in high transfer efficiency and less waste.
Production speed: Automatic spray guns coat parts at a much faster rate than human operators. For that reason, automated spray systems are ideal for applying coatings at high output rates.
Hazard avoidance: Removing direct operator involvement enhances safety with hazardous coatings.
Programmable and traceable: Spray locations, sequences, and volumes can be programmed for each part type. Modular automated spray stations can be arranged in different layouts. Automatic systems record real-time data on flow rates and operating parameters.
The main tradeoff is higher upfront investment compared to manual spray guns. But automation provides uniformity and high productivity for large finishing operations.
Paint pumps
Paint pumps are used in industrial finishing operations to transfer and deliver coating materials like paints, primers, varnishes, etc. They move coatings from storage tanks and deliver it to spray applicators, being them manual or automated.
A key reason to use paint pumps is that they provide consistent pressure to spray guns and other coating applicators. Also, they recirculate paint back to tanks for continuous agitation and mixing. Paint flow rates are precisely regulated based on application requirements.
For paint circulation it is essential to design a system with the flow requirements and the correct implementation of graduated lines. These systems are usually engineered by a professional paint circulation system designer.
Usually, paint pumps are made of non-corrosive materials like stainless steel. The most common types are diaphragm, piston, electric, etc. The ideal for your plant depends on the viscosity of the coatings. Proper paint pump selection and operation helps maintain finish quality while improving process efficiency and uptime.
Reasons to use paint pumps
Agitation and filtration: pumps continuously blend and agitate paint mixtures in storage tanks and mixing vessels. They also enable paint flows to be filtered to remove contaminants and prevent spray gun clogs. Paint pumps clear paint supply lines and spray guns of residual paint when changing colors to avoid contamination.
Paint circulation: Pumps transfer fresh paint from storage drums or vats into local reservoirs near paint booths. Also, they recirculate paint from reservoirs back into the supply system to keep solids suspended and prevent settling.
The paint circulation system must be configured appropriately for the flow, viscosity and usage requirements. There are various circulation configurations that are selected based on the coating process. For example, a constant color recirculation system may be different from a continuous color change system.
Paint recovery and control: Heated or chilled paint flows from pumps help maintain optimum coating viscosity for spray application.
Monitoring: Paint pumping systems are integrated with production control software and networks. Instrumentation from paint pumps provides data on real-time paint usage and flow rates.
Proper paint pumping improves finishing quality, reduces waste, and enables automated high-volume coating processes. Specifying the right paint pump for the application is important to save money and get the desired results.
Agitators
Agitators are used in industrial finishing processes to mix and continuously blend coating materials like paints, primers, varnishes, etc. They thoroughly mix paint ingredients together prior to application to ensure uniform distribution and can combine multiple component coatings and maintain homogeneity.
There are several types of agitators like impellers, anchors, propellers, turbines, and static mixers depending on the viscosity. The ideal mounting configuration (top-mount, side-mount, bottom-mount, or portable) might depend on the tank used.
The chosen agitator must provide sufficient mixing action for the coating formulation, so speed and torque should be taken into consideration.
Reasons to use agitators
Keeping solids suspended: Agitators prevent solids like pigments from settling out of paint mixtures during storage and processing. Keeping coatings mixed ensures smooth pumping to spray applicators.
Blending multi-component coatings: Static mixers blend separate coating components like catalysts together before spraying. Higher shear mixers can accelerate chemical crosslinking reactions for two-part coatings. Additional ingredients like texturing agents are dispersed into coatings using agitators.
Temperature control: Heated or chilled agitators help maintain optimum paint temperature in reservoirs. This way they can, among other things, prevent the formation of skins on top of paints in tanks from drying and ensures coatings have consistent viscosity and properties.
Flushing and cleaning: Agitators thoroughly rinse paint lines and pumps when changing colors and efficiently dissolve and disperse cleaning agents inside tanks and lines.
Proper agitation is essential for maintaining coating quality and reliability in finishing processes. The agitator design must suit the type of paint and application method.
Flow control and mixing devices
Flow control and mixing devices play a critical role in industrial finishing operations using multi-component coatings. They precisely meter and blend two or more coating components in the proper ratios. Static mixers provide rapid inline mixing of components just prior to application.
Reasons to use flow control and mixing devices
Color consistency and changers: Tinting colors are uniformly blended into coating bases using proportioners. Automatically switch between color component streams during changeovers. Proportioners accurately blend resins and cure agents like 2K urethanes or epoxies.
Data logging: Proportioners record real-time flow rates, mix ratios and other data to ensure proper blending ratios and for quality control. Material usage tracking helps forecast consumption and schedule refills.
Shot control: Some proportioners inject a precise shot of catalyst on demand to minimize waste and allow spray equipment like plural-component spray guns to be used remotely.
Process control: Flow rates and ratios are automatically adjusted by proportioners based on presets. Control fluid pressures to maintain consistent color proportion under varying conditions. Heat and cool fluids to optimize viscosity and mixing.
Other equipment used for industrial finishing
The beforementioned equipment is not the only ones in use in every industrial finishing plant. Also, filters, compressors, hoses, and other accessories are needed. When running an audit of your own plant, take them into account, because they can play a role in improving your overall operations.
This being said, let’s now consider ways to reduce costs in industrial finishing.
Reducing coating waste
When it comes to ways to reduce coating waste, there are several actions that can be taken.
- Use high transfer efficiency spray guns. HVLP (high volume, low pressure) and airless spray guns can greatly reduce overspray and waste versus conventional spray guns
- Use efficient spray techniques to reduce overspray. Training painters on maintaining the ideal spray distance and angle can minimize coating loss
- Use automated spray guns. Robotic and reciprocator spray systems provide very high transfer efficiency
- Adjust air and material flow rates. Optimizing air pressure and fluid tip/nozzle sizes reduces bounce back and overspray
- Schedule paint jobs efficiently. Coordinate jobs requiring the same coating in sequence to avoid changing systems
- Mix coatings carefully. Follow formulations and mix only required amounts to avoid leftover hardened coatings
- Implement inventory controls. Tightly manage coating inventory and shelf life to avoid expired materials. Set in place the FIFO (First-In-First-Out) system
- Repair defects judiciously. Use touch-up brushes only where needed versus re-spraying entire parts
- Reuse coatings. If you use powder coatings, you can recover and reuse them in a maximum proportion of 5-20% of the new powder coating.
- In-house recycling. Reclaim solvents onsite for reuse through distillation equipment. This reduces raw material costs. Safely collect and segregate coating wastes for outsourced recycling. Promote a culture of recycling in your plant
- Evaluate application method. Compare alternate coating methods. Evaluate less expensive coating options that still provide adequate protection.
- Audit regularly. Perform periodic audits and adjustments to identify additional waste reduction opportunities
Now, one thing is to reduce the coating waste and another quite different is to apply coating faster. Let’s consider that now.
Applying coating faster
Applying coating faster can be a way to reduce costs, because at the same time more units can be produced. There are several ways to increase the speed and efficiency of applying coatings in industrial finishing.
- Use automated coating equipment. Automated coating systems can improve transfer efficiency and reduce labor costs. Robotic spray coaters, dip coaters, roll coaters, etc. can apply coatings much faster than manual application. Evaluate ROI.
- Optimize viscosity. Coatings formulated to optimum spray viscosity will coat faster with less overspray
- Preheat parts. Preheating parts speeds cure times allowing faster recoating and throughput
- Use higher solids coatings. More solids mean higher build per pass. Consider waterborne coatings as well
- Adjust spray techniques. Narrower spray patterns, proper overlap, and keeping optimal distance from part increases transfer efficiency
- Employ recirculation. Use pots or drum recirculation to keep solids suspended improving flow and ability to spray
- Stage parts efficiently. Proper part staging and racking keeps parts accessible to painters minimizing delays
- Standardize settings. Establish optimal air pressure, fluid flow, tip size presets for common coatings and parts
- Upgrade compressed air. Inadequate CFM/pressure from compressors can slow application
- Balance workload. Cross-train employees and balance manual/automated lines to maximize throughput
- Perform maintenance. Well maintained spray booths and guns keep lines running optimally
- Consolidate coatings. Standardize fewer coatings and colors to improve purchasing leverage and inventory costs
- Optimize curing. Use IR, convection or other accelerated curing methods to speed recoating
- Lean operations. Optimize line layout and part flow to reduce material handling costs. Apply lean concepts to eliminate bottlenecks and activities that don’t add value to the process flow.
As you can see, there are many things to do to apply coatings faster. Another area to explore in order to reduce costs in industrial finishing, especially when manual labor is in place, is reducing the operator’s fatigue.
Reducing operator’s fatigue
Human operators will always be fatigued from doing a repetitive job day in and day out for several hours. Nevertheless, there are some effective ways to reduce operator’s fatigue in industrial finishing operations:
- Use ergonomic spray guns. Lighter weight, better balanced, easy triggering, and improved vibration damping features spray guns are way easier to use
- Provide gun lanyards. Shoulder straps or supports take static load off operators’ hands and arms
- Adjust workstations. Optimize working heights and locations to reduce awkward postures. Provide chairs or stools for tasks suitable to be performed sitting down.
- Automate when possible. Robotic or reciprocator systems perform tedious tasks consistently. This way you can use human operators only for specific tasks
- Rotate tasks. Vary tasks so operators use different muscle groups throughout shifts. Rotate painters between manual and automated stations
- Improve ventilation. Ensure adequate air exchange to remove solvent vapors and heat. Provide cooling vests or suits with ice packs or cooled water can reduce heat stress
- Training. Educate on proper spray techniques to avoid awkward motions. Cross-train employees to optimize labor and improve expertise. Stress efficient application techniques
- Stretching and exercises. Begin shifts with muscle stretches or light exercises. Encourage breaks to rest muscles and change position
- Monitor conditions. Track output, errors, fatigue reports to identify problems early
- Provide PPE. Comfortable respiratory protection, hearing protection, and protective apparel. Install anti-fatigue cushioned floor mats to reduce standing fatigue
The goal is to balance workload, provide ergonomic equipment, allow rest periods, and create a comfortable work environment. This helps maintain operator health, productivity and quality results.
Reducing rework
Reworks are to be avoided because they can cause bottlenecks, reduce speed, and increase costs. Here are some effective strategies to reduce rework in industrial finishing operations:
- Implement robust quality control procedures. Thoroughly inspect parts at multiple stages of the finishing process to catch defects early. Keep spray booths, storage areas, and tools clean to avoid dust nibs or debris in finishes
- Standardize finishing procedures. Develop and document standardized paint application methods, equipment settings, color mixes, etc. Work with suppliers to fine-tune coatings for your specific application to prevent flaws.
- Improve worker training. Invest in training painters and inspectors on proper techniques to minimize errors
- Upgrade equipment. Use automated or robotic paint systems to remove variability from manual application work
- Enhance traceability. Track parts through the process digitally so any issues can be traced to the root cause. Track defect types, rates, and causes to identify opportunities for systemic improvement.
- Validate curing. Ensure coatings are fully cured before recoating or handling to avoid damage. Add resources or capacity to avoid rushed handling that can cause defects
- Maintenance. Proper spray gun and equipment maintenance improve efficiency and reduce downtime. Follow preventive schedules. Proper maintenance prevents flaws from clogs, wear, or misalignment through preventive maintenance
- Improve part fixturing. Sturdy, precise part jigs and fixtures prevent fit issues between steps
- Involve team. Get input from painters, quality personnel, and others to identify rework root causes
- Fix problems at source. When defects occur, fully resolve the underlying process issues rather than repeated quick fixes
Of course, it is always stressful when problems on the production line arise. Having a culture of solving problems immediately can help to avoid bigger problems in the future. Let’s now see another way to reduce costs in industrial finishing operations.
Buy supplies in huge quantities
When you buy in bulk, huge quantities, you can get discounts. Also, the suppliers give you some preferences. This can be useful to enjoy some promotions, when they come out with that. Here are some tips for purchasing supplies in large quantities for industrial finishing operations:
- Assess usage. Analyze historical usage data to accurately estimate the quantity needed before making large purchases. Factor in any projected changes in production
- Negotiate discounts. Work with vendors to negotiate price discounts for committing to large volume purchases. Explore contract pricing for steady volumes overtime
- Seek package deals. Look for opportunities to bundle purchases across multiple supply categories to maximize leverage in negotiations
- Coordinate with other departments. Partner with operations, maintenance, etc. to anticipate needs company-wide and combine orders
- Determine logistics. Ensure there is sufficient storage space for large inventories. Define material handling procedures and equipment needs
- Manage inventory. Use inventory management software and practices like FIFO (first-in-first-out) to avoid excessive expiration of shelf-life limited materials
- Phase purchases. Consider spreading out the buying of very large quantities over an extended timeframe to balance supply and demand
- Review quality. For new suppliers, thoroughly vet product quality before committing to high volumes
- Analyze total cost. Weigh benefits of lower unit costs against tied-up cash flow and burdens of high inventory
- Mitigate risks. Diversify sources and supply channels to reduce vulnerability to shortages from a single provider
Careful planning and cost analysis is key to realizing the advantages of volume purchasing without undue inventory burdens. This could lead to savings in your industrial finishing operations. Another thing that is fundamental is optimizing the workflow. Let’s see how to do that.
Optimize the workflow
Here are some tips for optimizing workflow and efficiency in industrial finishing operations:
- Perform process mapping. Visually map out each step and identify opportunities to streamline or consolidate steps
- Eliminate bottlenecks. Target areas causing slowdowns like manual masking or long curing times for improvement. Add resources like jigs or ovens if needed
- Standardize processes. Develop procedures to ensure consistent parts finishing and make best practices easier to follow
- Optimize part flow. Design process layout to minimize the unnecessary transportation and handling of parts between stations
- Testing and QA. Optimize testing protocols to reduce costs but still ensure quality
- Implement 5S. Maintain an organized workplace, store items used most often closest, eliminate unnecessary items
- Cross-train employees. Train staff across multiple functions to allow for load balancing and more flexible assignment
- Leverage automation. Use automated conveyors, guided vehicles or robots to transport parts reliably without human involvement
- Schedule effectively. Sequence jobs needing common coatings/equipment together to minimize changeover. Schedule urgent jobs first
- Enhance communication. Keep teams informed of schedules, workloads and priorities to coordinate efforts
- Track metrics. Collect cycle times, throughput, defects and other metrics to continuously improve
- Maintain equipment. Prevent breakdowns that cause delays through predictive maintenance and PM programs
- Seek input. Involve team members to contribute ideas for improving efficiency and output
- Apply lean principles. Eliminate any waste and inefficiencies in the process including overproduction, waiting, and excess transport.
Of course, these tips can be useful not only in the industrial finishing production area, but also in company-wide activities. Finally, one of the best ways to reduce costs in industrial finishing is by using state-of-the-art equipment.
Get state-of-the-art equipment
Here are some of the major advantages of investing in new, state-of-the-art equipment for industrial finishing operations:
- Improved quality. The latest spray guns, ovens, and other equipment often provide better process control resulting in more consistent, flawless finishes
- Increased efficiency. Automated lines and robotic coaters can achieve much higher throughput with less labor compared to manual application
- Energy efficiency. Use efficient motors, lighting and HVAC in coating areas to reduce utility costs
- Reduced defects. Precision programmable equipment and instrumentation help avoid human errors and rework
- Lower emissions. Newer coating equipment incorporates designs that minimize overspray and VOC emissions
- Lower maintenance. New equipment with improved components and diagnostics requires less maintenance downtime
- Enhanced data collection. Smart systems provide detailed production data for performance optimization
- Smaller footprint. Space-saving equipment layout options help reduce facility costs
- Consistent output. Robotic coaters repeat the exact same process throughout long production runs
- Improved ergonomics. Better designed equipment reduces fatigue and injury risks for operators
- Better coatings. Advanced equipment allows use of newer high-performance coating formulations
- Competitive edge. State-of-the-art finishing provides a differentiation opportunity and prestige
- Employee retention. A modern workplace and new challenges help retain talented workers
While requiring considerable upfront investment, upgrading to the latest finishing equipment can provide significant quality, productivity and brand reputation benefits. Since we have been working with industrial finishing for over 40 years, we have seen a lot of changes in the equipment used. We can help you to define the ideal set of industrial finishing equipment for your production plant.
The real solution to reduce costs in industrial finishing
You will be able to reduce costs in industrial finishing by applying as much as possible all the suggestions contained in this article. Each one of them can bring some savings, so it is the total of them what can really make a difference.
It would be a good idea to make a plan to apply these suggestions. Depending on your own circumstances, this plan can be completed in a short time or in the long term. Nevertheless, one thing is sure: If you don’t plan the changes you consider your plant needs to make, it’s not going to happen.
One you have decided to make some changes, you might need another mind to help you to define some details in your plan. Here is when an expert comes handy. We have seen time and again how companies have been able to overcome industrial finishing problems that seemed to be out of reach. We also have assisted many to define what industrial finishing equipment they need, and how all the production plant should work. Feel free to reach out to us to help you too.
