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Minimizing Paint Waste - PowerPoint PPT Presentation

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Minimizing Paint Waste. Environmental & Health Concerns. Hazardous waste Mixed coatings and solvent Toxic, flammable Air emissions Toxic constituents Toluene, xylene, MEK Smog forming VOCs. Paint Waste Sources. Mixing room Overestimate Overmix Overspray Technique Equipment

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Environmental & Health Concerns

  • Hazardous waste

    • Mixed coatings and solvent

    • Toxic, flammable

  • Air emissions

    • Toxic constituents

      • Toluene, xylene, MEK

    • Smog forming VOCs

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Paint Waste Sources

  • Mixing room

    • Overestimate

    • Overmix

  • Overspray

    • Technique

    • Equipment

  • Re-work jobs

    • Color not matched

    • Dust and dirt

    • Finish quality

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Manage Inventory

  • Just-in-time ordering

  • First-in, first-out

  • Keep containers closed

  • Mixing banks

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Color Matching

  • Mix in small amounts

    • Start with 8 oz. or less

  • Spray out on test panels

    • View and compare in natural light

  • Colorimeter or spectrophotometer

  • Expertise of other painters

  • Color library of spray-outs

    • Record color mix information

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Paint Measurement

  • Computerized mixing system

    • Tracks product use and VOCs

    • Reports for air district

  • Automated paint dispenser

    • Minimizes over-pours

  • Minimize paint transfers

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Track and Troubleshoot

  • Record each step

    • Estimated amount

    • Actual amount mixed

    • Left over

  • Compare estimated and actual paint used to refine estimating

  • Compare paint orders with workload

  • Work with painter to resolve

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Paint left over

  • Mix into ground coat

    • Cover hard to hide colors

    • Under dark color coat

    • Will it change regulated VOC content?

      • Check with air district

  • Door interiors, edging, jambing

  • Save popular colors for later use

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  • Mix in cup liner

  • Mix more than one batch at a time

  • Increases application efficiency and reduces paint overspray

  • Cover and save mixed paint for a limited time

  • Reduces cleaning solvent and waste

    • Do not need to clean paint pot

    • Reduces labor

  • Increased production

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Job Planning

  • Primer and clear coat back-to-back

  • Tintable primer systems

  • Schedule waterborne primer application to allow drying time

  • Remove part before painting

    • No masking needed

    • Reduces overspray

    • Streamlines process

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  • Spray efficiency

    • Finish quality

    • Transfer efficiency (TE)

      • How much paint gets on the surface

    • Build efficiency (BE)

      • Amount of build (mils) applied on surface compared to amount sprayed

  • Many variables effect spray efficiency

    • Technique

    • Equipment and settings

    • Correct use of product

    • Part geometry

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Improve Spray Efficiency

Poor technique

  • Wastes paint

  • More clean-up

  • Painter labor

  • Paint technician training

  • Technology

    • Higher efficiency spray guns

    • Targeting device for training and application

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    Painter Training

    Painters learn to apply paint more efficiently

    • Hands-on training

    • Students practice proper technique

    • Techniques for specific coatings

  • I-CAR training centers

  • Paint manufacturer training

  • Community college automotive programs

    • IWRC STAR ® Program,Spray Technique Analysis and Research


    • LA Trade Technical College

  • IWRC STAR training for defense


  • ARB P2 web page- auto refinishing


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    • LaserPaint™

      • Application technique and targeting tool

      • Allows painter to:

        • Maintain correct angle and distance for consistent coverage

        • Optimize overlap

        • Reduce overspray

      • Developed by Iowa Waste Reduction Center (IWRC)


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    Cost: $300 includes mounting bracket and training CD

    LaserPaint tool developed by IWRC

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    Environmental Technology Verification

    • LaserPaint

      • ARB certified performance claim

      • 15% volume reduction average

      • USEPA environmental technology verification (ETV) May 2000

    • High TE Spray Equipment

      • ETV report

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    Virtual Paint- computer simulated training

    Painter Training

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    Virtual Paint

    • Painters learn proper technique

      • Reduces waste and costs

    • Advantages

      • No paint waste- booth and filters, equipment, clothing

      • No air emissions

      • No clean up waste

    • Disadvantages

      • High cost of technology

      • Availability

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    Functions of Spray Booths

    • Facilitates cleaner paint jobs

      • Contains overspray

      • Collects waste

      • Provides clean air during paint operations

      • Provides well lit area, devoid of dust

    • Protects worker’s health

      • Confines harmful emissions in one area

        • Prevents workers outside of booth from inhaling solvent emissions and paint particles

        • Workers painting within booth should wear personal protective equipment

    • Monetary savings

      • Reduces operation costs

      • Lowers labor costs

      • Reduces material costs

    • Filters paint particles from air before exhausting it into the atmosphere

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    Types of Paint Spray Booths

    • Spray booths provide uniform airflow

    • Two most common types of spray booths

      (1) Cross draft spray booth

      (2) Down draft spray booth

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    Cross Draft Spray Booth

    • Air is drawn in across filters on the front end of the room into filters located on the opposite end of the room.

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    Down Draft Spray Booths

    Air is pulled down through inlet filters on the ceiling into exhaust filters located on the floor.

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    Combination Drying Booths

    • Two distinct operating cycles

      (1) Painting

      (2) Heated drying cycle

    • Decreases curing time

      • High productivity due to fast processing time

    • Allows for good finish quality and reduces re-working

    • Conserves energy

      • Uses recirculating airflow

    • More cost effective over lifespan of equipment

      • Reduces costs

        • Operation and maintenance

        • Labor

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    Spray Booth Considerations

    • Serviceability

      • Select from a vendor that offers maintenance, support, and warranty

      • Choose a vendor that is accessible to reduce downtime when replacement parts and/or repairs are needed

    • Lighting

      • Fluorescent

        • Runs cooler

        • Consumes less energy

      • High-Intensity Discharge (HID)

        • Delivers more lighting per lamp

        • Requires longer warm-up time

    • Filter

      • Most important component of a spray booth, must be capable of holding and capturing all dirt, overspray, and solvent

      • Prevents paint build-up on fans, exhaust, and release of paint particulates into the environment

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    Paint Spray Booth Interior – Down Draft Spray Booth

    Ceiling Air Inlet, filters above inlets

    Polyethylene Sheeting/ Masking Cling Film



    Filters beneath grates

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    Maintain Spray Booth and Components

    • Produces cleaner paint jobs, reduces waste, and protects worker’s health

    • Results in lower labor costs, reduces operation costs, and reduces material costs

    • Develop a routine maintenance schedule that includes:

      • Changing filters

      • Masking off booth surface and equipment

      • Checking paint buildup on fans

      • Overall good housekeeping

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    Maintain Spray Booth

    Manometer- check routinely for optimum air flow

    Keep booth clean

    Remove dust and debris

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    Paint Waste Reduction

    • Waste reduction equates to cost savings for shops

    • Employee incentives

      • Ask for their ideas

      • Share cost savings of significant waste reduction with workers

      • Allow time and incentives for training refreshers