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Tier 1 Automotive Supplier Speeds Up Production
Rotary bell atomiser upgrade reduces cleaning frequency and advances quality in flocking booth.
New Air Caps Help Increase Transfer Efficiency by 15%
CUSTOMER: Tier 1 automotive supplier
GRACO EQUIPMENT: ProBell rotary bell atomisers
A leading component manufacturer produces gas springs, damping solutions and electromechanical drives for the automotive industry. In their factory’s flocking booth, they use Graco ProBell rotary bell atomizers to spray adhesive onto coil springs, so that they could be coated with noise dampening fibres.
CHALLENGE: The flocking manager experienced good spray performance with ProBell, but the need to clean or wipe off the air cap – sometimes two to three times a day – impeded production. To mitigate downtime, they kept three spare air caps soaking in solvent, ready to be changed out.
In addition, the company wanted to speed up production. Flocking technicians tried to improve transfer efficiency by lowering flow rates to the rotary bell atomiser. But they could go no lower than 150 to 180 cc/minute.
SOLUTION: The flocking manager agreed to test Graco’s next generation air caps for ProBell rotary bell atomisers. Together, the manager and his local Graco representatives observed spray performance and cleaning frequency, letting the upgraded air cap run for more than a month.
The upgraded air cap installation quickly proved its worth, improving upon these Graco ProBell advantages:
- Blended shaping air for high quality spray
- Compact size and small diameter for tight spaces
- Power supply with low voltage for better safety and less complexity
- Stainless steel air cap cover that protects bell and air cups
RESULTS: With the new Graco ProBell air cap, the manufacturer saw immediate improvements.
- The need to clean happened only once a week. Wiping off the adhesive was much easier, thanks to the air cap’s new hole design.
- Flocking technicians could decrease flow rates to 140-160 cc/minute, improving transfer efficiency by 15 per cent. This helped speed up production and generate less waste.
What is flocking?
Flocking is the application of millions of tiny fibres (called “flock”) onto an adhesive-coated surface to create a velvet-like texture. Automakers use this process to finish glove boxes, centre consoles and other areas inside of a vehicle. Flocking also is used to protect metal springs, reducing friction and noise throughout the vehicle.
Tier 1 automotive supplier
OEMs (original equipment manufacturers) demand components that look good and work well under harsh conditions. Tier 1 suppliers throughout the automotive industry achieve durable coatings and precise fluid dispense with Graco solutions.
