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System Design

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NEW!

The Systems Design for Industrial Finishing Applications is the latest manual to receive a complete re-write.  The new manual provides innovative and updated information on all the essential factors for setting up and running efficient finishing systems. From layout to spray booths, washers, ovens, conveyors and more, this manual reviews the key elements of finishing systems design.  The design and operation of an industrial finishing system is a very involved process that can be managed if the operator has a proper understanding of the system equipment and good process control.  This manual attempts to provide an understanding of the equipment and process issues that impact the design and operation of a finishing system. 

Every single paint finishing system is different.  The equipment, coating, and process are all uniquely joined like no other system in the world.  But the goals of the operator are the same; produce a consistent high quality finish at a reasonable cost in compliance with all applicable rules and regulations.  The concepts and standards outlined in this book can be adapted to any unique situation to help guide the operation.  But like a high quality automobile that does not get regular oil changes, a paint system cannot deliver peak performance without regular maintenance and solid control of the system variables.  For this reason, it is stressed above all else, that the operation of the system be documented and controlled, and that all equipment is properly maintained to avoid the unnecessary problems.

Table of Contents

CHAPTER

TITLE

1

SYSTEM LAYOUT

 

 

2

SPRAY BOOTHS

 

Spray Booth Sizing

 

Filtration

 

NFPA Requirements

 

 

3

SPRAY WASHERS

 

Mechanical Cleaning

 

Chemical Cleaning

 

Spray Washer Sizing

 

Solution Tanks

 

Drainage Spaces

 

Tank and Housing Materials

 

Zinc Phosphate Tank

 

Sludge Removal

 

Screens

 

Access Doors, Ladders and Lighting

 

Equipment Exhaust System

 

Conveyor Shroud

 

Pumps and Spray Systems

 

Riser Spacing

 

Nozzles

 

Gauges

 

Solution Heating

 

Operating Temperature and Time Cycle

 

High-Velocity Blow-Off   

 

Water Conservation

 

 

4

OVENS

 

Construction

 

Heat Source

 

Dry-Off Ovens

 

Cure Ovens

 

Combination Ovens

 

Heat Containment

 

 

5

CONVEYORS

 

General Design

 

Design Centers

 

Lubrication

 

Inspection

 

Sanitary Pan

 

Inverted Box Track

 

Power and Free

 

Friction Drive

 

Fixed Angle Friction Drive Wheel

 

Friction Belt Drive

 

Control System

 

Hook and Rack Considerations

6

COATING PROCESSES

 

High Solids

 

Waterborne Coatings

 

Powder Coatings

 

Electrodeposition

 

Autodeposition

 

 

7

VOC ABATEMENT

 

Thermal Solutions

 

Adsorption Solutions

 

Absorption Solutions

 

 

8

MAXIMIZING THROUGHPUT & MINIMIZING WASTE

 

A Holistic Approach

 

Engaging & Training the Team

 

The Seven Deadly Wastes on the Coating Line

 

 

9

WASTE REDUCTION & TREATMENT

 

Pretreatments Waste

 

Oils and Metals

 

Waste Treatment Systems

 

Treat for Discharge Systems

 

Paint Wastes

 

 

10

SYSTEM OPERATING EXPENSES

 

Cost of Pretreatment

 

Cost of Coating Materials

 

Utility Costs

 

Capital Costs

 

Other Costs to Consider

 

 

11

AIR MAKEUP AND VENTILATION

 

Air Management

 

Air Makeup Units

 

 

12

QUALITY CONTROL

 

Define Process Requirements

 

System Design

 

Potential Sources of Paint Defects

 

How Racking Affects Quality

 

Process Control