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Minimizing Paint Waste

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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Minimizing Paint Waste

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  1. Minimizing Paint Waste

  2. Environmental & Health Concerns • Hazardous waste • Mixed coatings and solvent • Toxic, flammable • Air emissions • Toxic constituents • Toluene, xylene, MEK • Smog forming VOCs

  3. Paint Waste Sources • Mixing room • Overestimate • Overmix • Overspray • Technique • Equipment • Re-work jobs • Color not matched • Dust and dirt • Finish quality

  4. Manage Inventory • Just-in-time ordering • First-in, first-out • Keep containers closed • Mixing banks

  5. 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

  6. Paint Measurement • Computerized mixing system • Tracks product use and VOCs • Reports for air district • Automated paint dispenser • Minimizes over-pours • Minimize paint transfers

  7. 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

  8. 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

  9. Calibrated Liners

  10. Advantages • 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

  11. 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

  12. Painting • 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

  13. 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

  14. 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 • http://www.iwrc.org/STAR/STARschools.htm • LA Trade Technical College • IWRC STAR training for defense • http://www.star4d.org • ARB P2 web page- auto refinishing • http://www.arb.ca.gov/coatings/p2/overview.htm

  15. Technology • 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) • http://www.laserpaint.us

  16. Cost: $300 includes mounting bracket and training CD LaserPaint tool developed by IWRC http://www.laserpaint.us

  17. Environmental Technology Verification • LaserPaint • ARB certified performance claim • 15% volume reduction average • USEPA environmental technology verification (ETV) May 2000 http://www.epa.gov/etv/verifications/vcenter6-5.html • High TE Spray Equipment • ETV report http://www.epa.gov/etv/verifications/vcenter6-16.html

  18. Virtual Paint- computer simulated training http://www.virtualpaint.us/ Painter Training

  19. 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

  20. Paint Spray Booths

  21. 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

  22. 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

  23. 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.

  24. Down Draft Spray Booths Air is pulled down through inlet filters on the ceiling into exhaust filters located on the floor.

  25. 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

  26. 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

  27. Paint Spray Booth Interior – Down Draft Spray Booth Ceiling Air Inlet, filters above inlets Polyethylene Sheeting/ Masking Cling Film FluorescentLighting Grates Filters beneath grates

  28. Air Intake and Filters

  29. 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

  30. Maintain Spray Booth Manometer- check routinely for optimum air flow Keep booth clean Remove dust and debris

  31. 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

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