STAR  Increased Profits Through Efficient Spraying

STARIncreased Profits Through Efficient Spraying Ken Grimm Pacific Northwest Pollution Prevention Resource Center (PPRC) Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying What is PPRC? We are the leading regional non-profit that provides practical, on-the-ground technical assistance to businesses, public agencies and non-profits that are seeking to conserve resources and improve economic performance. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying What is PPRC? http://www.pprc.org http://www.p2rx.org One of eight regional centers encompassing the entire United States Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Our Goal Today • Get familiar with new surface coating requirements Area Source Rule Subpart HHHHHH • Get familiar with the elements of the STAR manual spray efficiency program • Meet the NESHAP training requirements Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying NESHAP Standard Requires: • All Painters complete training in techniques to minimize paint overspray • No spray gun cleaning by spraying solvent that creates an atomizing mist • Routine spray booth and filter maintenance • High efficiency spray guns • Documentation of compliance Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying NESHAP Standard Requires: • Initial training – valid for a period of 5 years • Refresher training at least once every 5 years • Training completed by 3 years from NESHAP date (1/10/2011) or 180 days after hiring. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying NESHAP Standard Requires: • Initial and Refresher training must address spray gun equipment selection, set-up and operation, including: • Measuring coating viscosity • Selecting proper fluid tip and nozzle • Achieving proper spray pattern • Achieving proper air pressure and volume • Achieving proper fluid delivery rate Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying NESHAP Standard Requires: • Improve transfer efficiency and minimize coating usage and overspray by: • Maintaining correct spray gun distance and angle • Using proper banding and overlap • Reducing lead and lag Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Why Address Collision Repair? • Aggregated affect: The following table lists the toxic weighted (cancer risk) emissions of various sectors in the United States. Figures are tons per year. • Source:EPA area source category list – 21 sectors. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Why Address Collision Repair? Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying NESHAP Standard Requires:Paint Booths • Spray applied coatings must be done in a booth or a prep station • Large enough to hold complete vehicle: • Four complete side walls or curtains • Complete roof • Subassemblies or parts • Three complete side walls or curtains • Complete roof Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying NESHAP Standard Requires:Filter Efficiency Requirements • Filters now required to be 98% efficient. • Must have certification that filters meet this requirement • Paint Arrestance Filter Test Report Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying NESHAP Standard Includes:Methylene Chloride Paint Stripper • Investigate alternatives. • Optimize application conditions. • Practice proper storage and disposal • Maintain records of annual usage • Develop and implement MeCl minimization plan if usage ≥ 1 ton. “must implement management practices that reduce emissions of MeCl by minimizing evaporative loss.” Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying STAR Program History • The STAR Training Program started in 1994 • Applied research project funded by the Small Business Administration and the EPA • Project’s goal: determine the most cost effective and practical approach to improving manual spray efficiency in the automotive refinishing industry. • The study resulted in a focus on improving spray efficiency through technician training. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Variables Affecting Spray Efficiency(Uncontrollable Variables) • Air Supply System • Booth Conditions • Air flow rate and direction • Relative humidity • Operation space • Lighting Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Variables Affecting Spray Efficiency(Uncontrollable Variables) • Size and geometry of part • Coating type and color • Coating mil thickness requirements • Finish quality requirements Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Variables Affecting Spray Efficiency(Controllable Variables) • Mixture Content • Booth Operating Temperature • Spray Equipment Type • Equipment Maintenance Practices • Gun Setup Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Variables Affecting Spray Efficiency(Controllable Variables) • Spray Distance • Spray Angle • Spray Techniques • Advanced Techniques • Plan Of Attack Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying What Is Transfer Efficiency? Transfer efficiency is the measurement of how much paint sprayed is actually applied to the part being painted. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Transfer Efficiency = Mass of solids deposited Mass of solids sprayed Or Transfer Efficiency = Volume of solids deposited Volume of solids sprayed How is Transfer Efficiency Measured? Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Why Is Transfer Efficiency Important? • Material savings: Increased transfer efficiency reduces material usage. • Health impact:Toxins, solvents, and other ingredients can cause adverse health impacts. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Health Impacts Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Why Is Transfer Efficiency Important? • Environmental impacts: Volatile organic compounds (VOC’s) are air pollutants which produce ozone (smog). • Reduced environmental liabilities: Reduction in the pollutants emitted will reduce liability and may reduce regulatory burden. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Why Is Transfer Efficiency Important? • Even good, experienced painters frequently have a transfer efficiency of 50 % or less. • Even a 10% improvement in transfer efficiency can have dramatic affects on costs and air emissions. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying 40% Transfer Efficiency Why Is Transfer Efficiency Important? Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Why Is Transfer Efficiency Important? Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Transfer Efficiency Shortcomings Transfer efficiency is not the best means of measuring the efficiency of a paint system because it does not consider the build of the coating applied. To account for build difference, build efficiency is used. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying What Is Build Efficiency? Build Efficiency = Avg. Mils Applied x Area Sprayed Mass of Paint Sprayed Or The amount of build you get out of the paint you spray • Consistency is the key to build efficiency. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying STAR Spray Techniques • Spray gun distance to part • Perpendicular to surface • Spray angle • Consistent 50% overlap • Banding and edging • Reduce lead and lag Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Mixture Content • Choice of thinner/reducer:Choose the product recommended by the manufacturer for the material being sprayed and spray conditions. • Mixing ratio:Mix according to the manufacturer’s requirements. Do not over reduce. Occasionally take Zahn readings to ensure proper viscosity. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Spray Equipment Type • Choice of equipment should be based on the coating type. • Choose equipment that will effectively atomize the coating at a low PSI setting. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Spray Equipment Maintenance Practices Guns must be cleaned and maintained regularly to ensure optimum atomization and spray pattern. Spray Technique Applied Research PPRC

STARincreased Profits Through Efficient Spraying Gun Setup • Fan Setting. • Fan setting should be appropriate for the geometry of the part being sprayed. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Gun Setup • Gun Pattern • Know the shape and size of your spray pattern at full and partial trigger. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Gun Setup • Use the spray pattern to your advantage. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Gun Setup • Air Pressure Settings • Air pressure should be set at the lowest setting that allows adequate atomization. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Gun Setup • Air pressure too high = • Low transfer efficiency • Wasted material • Excessive overspray • Low film build • Poor finish quality Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Gun Setup • Air pressure too low = • “Heavy-centered spray pattern • Excessive film build • Orange peel • Runs / sags Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Spray Distance Gun distance should follow the manufacturer’s recommendation for both gun and product being applied. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Gun Setup • Fluid setting • High fluid settings require high air pressure to properly atomize the coating. • Keep fluid setting as low as possible while still maintaining comfortable gun speed. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Gun Setup • Fluid delivery too high = • Runs or sags • Solvent popping • Excessive film build • Poor atomization Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Gun Setup • Fluid delivery too low • Dry spray • Low film build • Multiple coats required • Lower productivity Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Spray Distance Keep the distance consistant. Spray Technique Applied Research PPRC

STARIncreased Profits Through Efficient Spraying Spray Distance Spray Technique Applied Research PPRC

STAR  Increased Profits Through Efficient Spraying