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Reducing Energy Usage In Paint Systems

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    1. Cutting Paint Finishing Energy Usage in Manufacturing Plants High energy pricing has significantly raised the importance of minimizing energy use in manufacturing plants. This talk will present advanced strategies, technologies and methodologies that can cut energy usage in the paint finishing system in half. Implementation strategies are included for both new and existing systems. Cutting Paint Finishing Energy Usage in Manufacturing Plants High energy pricing has significantly raised the importance of minimizing energy use in manufacturing plants. This talk will present advanced strategies, technologies and methodologies that can cut energy usage in the paint finishing system in half. Implementation strategies are included for both new and existing systems.

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    3. An Energy Saving Driver As you know, the trend in annual energy costs continues to rise In a manufacturing assembly plan, the product finishing department is one of the largest energy users in many cases the finishing process can account for half of the energy consumed by the entire manufacturing assembly process This makes the finishing department a prime target for implementing energy reduction technologies and processes. As shown in the right column, the large swings in energy costs can significantly impact your bottom line. The annual energy cost of each shift costs about $64K Therefore a system running two shift costs about $130K for energy So if we can make some changes that cut energy usage in half, we can add about $65K in annual profit. With this kind of savings, the ROI to implement these changes is very attractive. Lets take a look at what types of changes are needed to cut energy usage in half. As you know, the trend in annual energy costs continues to rise In a manufacturing assembly plan, the product finishing department is one of the largest energy users in many cases the finishing process can account for half of the energy consumed by the entire manufacturing assembly process This makes the finishing department a prime target for implementing energy reduction technologies and processes. As shown in the right column, the large swings in energy costs can significantly impact your bottom line. The annual energy cost of each shift costs about $64K Therefore a system running two shift costs about $130K for energy So if we can make some changes that cut energy usage in half, we can add about $65K in annual profit. With this kind of savings, the ROI to implement these changes is very attractive. Lets take a look at what types of changes are needed to cut energy usage in half.

    4. Two Basic Ways to Save Energy

    5. System Design - Washer Washer Chemistry Minimizes heat requirements Low Temp Cleaners (140 F 110F) Low Temp iron phosphate (140 F Amb) Basic Washer Design Air Flow Control Tank Covers Recycle rinse water into chemical bath Water Pre-Heated

    6. Chemistry Operating Energy

    7. System Design - Paints Select paints that cure at low temperatures Powders Liquids

    8. System Design Air Heat Seal An invisible air curtain prevents hot air from escaping Reduces energy usage up to 65% Increases Oven Efficiency by 10% (energy to product) 2,500,000 BTU /HR to 1,900,000 BTU / HR Maximizes cure window greater production rates Works on Ovens and Washers Precise & Programmable Oven Control Precise & Programmable Oven Control

    9. System Design - Pyrolytic Burn-Off Oven Removes paint from fixtures ABMyr design operates at air mixture with high BTU capacity

    10. Operations Automate & Control

    11. Operations Automate & Control

    12. Upgrading Existing Paint Systems Common Upgrade Kits Pre-treatment washer upgrade kit Oven upgrade kit Air heat seals kit Paint Line Manager kit Air management upgrade kit

    13. Cure Oven Upgrade Example Typical cost = $100K Benefits: Reduces energy usage up to 65% Precise temperature control improves curing performance Enables increased line speed & production rate

    14. Typical Savings Ratios

    15. 15 Energy Saving Installation Example Tennant Company Complete Paint Finishing System Washer, Oven, Powder Coating Booth Energy saving methods: Cure Oven and Washer Air Barrier Heat Seals Automated Process Controllers Savings: 50% reduction in energy usage and costs The next couple slides show how a few manufacturers are using ChemOPS to improve their paint system operations. Tennant Company, located in Minnesota, makes a large variety of floor sweepers. ChemOPS enables Tennant to monitor the paint system operation from a single centralized supervisory system control PC. ChemOPS automatically controls the pre-treatment washer sub-system as well as the temperature profile of the curing oven to significantly boost paint system performance. Bob Boothby, Tennant principle manufacturing engineer in charge of the paint system, provided a quote on how the ChemOPS process controller is a playing a big factor in their success and is enabling Tennant to continually improve their quality.The next couple slides show how a few manufacturers are using ChemOPS to improve their paint system operations. Tennant Company, located in Minnesota, makes a large variety of floor sweepers. ChemOPS enables Tennant to monitor the paint system operation from a single centralized supervisory system control PC. ChemOPS automatically controls the pre-treatment washer sub-system as well as the temperature profile of the curing oven to significantly boost paint system performance. Bob Boothby, Tennant principle manufacturing engineer in charge of the paint system, provided a quote on how the ChemOPS process controller is a playing a big factor in their success and is enabling Tennant to continually improve their quality.

    16. Industrial Publication Industrial focused newsletter Energy-saving technologies Paint Finishing Systems Factory Air Ventilation Systems Metal Fabrication To receive a copy: Drop off your business card or send email to: Service@ABMyr.com

    17. Contact Information